851 Product Manual

June 2008
Safety Information in this Manual

Danger, Warning, and Caution symbols are used throughout the manual to help identify and
avoid hazardous situations. Examples of each symbol are shown and explained below.
DANGER
Indicates an imminently hazardous situation that, if not avoided, will result in
death or serious injury. This signal word is to be limited to the most extreme
situations. It may also be used to alert against unsafe practices. (Color: red)
WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in
death or serious injury. It may also be used to alert against unsafe practices or
cause product failure. (Color: orange)
Caution
Indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe
practices. (Color: yellow)
Table of Contents
Chapter 1........................................................................................1-1
Product Description......................................................................... 1-1
Phase-Angle Control..................................................................... 1-2
Zero-Crossover Control ................................................................ 1-4
Standard Features ........................................................................ 1-7
Optional Features ......................................................................... 1-8
Technical Specifications ............................................................... 1-9
Floating Point Data and Current Range ...................................... 1-10
Part Number ............................................................................... 1-10
Chapter 2........................................................................................2-1
Hardware ........................................................................................ 2-1
Installation..................................................................................... 2-1
Enclosure...................................................................................... 2-1
Enclosure Temperature ................................................................ 2-1
Vibration........................................................................................ 2-1
Mounting ....................................................................................... 2-2
Disconnect Means ........................................................................ 2-2
Wiring............................................................................................ 2-2
Remote Feedback Wiring ............................................................. 2-5
Control Connections ..................................................................... 2-6
Digital Inputs ..................................... Error! Bookmark not defined.
Digital Outputs .............................................................................. 2-9
Analog Input...................................... Error! Bookmark not defined.
Analog Output ............................................................................. 2-11
Remote Feedback....................................................................... 2-11
Over-temperature Sensing.......................................................... 2-11
Chapter 3........................................................................................3-1
Configuration................................................................................... 3-1
Startup .......................................................................................... 3-1
Configuration Tool Installation ...................................................... 3-2
Running the Configuration Tool .................................................... 3-3
Configuration Tool Menu and Task Bar Descriptions.................... 3-5
Off-line Programming.................................................................. 3-10
On-line Programming.................................................................. 3-17
On-line Monitor ........................................................................... 3-22
Fault History................................................................................ 3-25
i
Flash Programming..................................................................... 3-26
Loss of Communication .............................................................. 3-27
Chapter 4........................................................................................4-1
Calibration....................................................................................... 4-1
Current Rating............................................................................... 4-3
Voltage Rating .............................................................................. 4-3
Remote Voltage and Current Feedback........................................ 4-4
Calibration Procedure ................................................................... 4-5
Saving Calibration......................................................................... 4-7
Restoring Factory Calibration ....................................................... 4-8
Analog Calibration....................................................................... 4-10
Manual Calibration ...................................................................... 4-13
Magnetizing Sequence Calibration ............................................. 4-14
Repetitive Pulse Calibration........................................................ 4-14
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 Protocol – MODBUS RTU................................................... 6-3
Floating Point Data and Current Scaling....................................... 6-5
Additional Serial Information ......................................................... 6-6
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 Actual...................................................................... 7-1
Voltage Input Span ....................................................................... 7-2
Frequency Rating.......................................................................... 7-2
Frequency Actual .......................................................................... 7-2
Voltage Output Rating................................................................... 7-2
Voltage Output PT Secondary ...................................................... 7-2
Voltage Output Limit ..................................................................... 7-2
ii
Voltage Output Setpoint................................................................ 7-2
Voltage Output Proportional Gain ................................................. 7-2
Voltage Output Integral Gain ........................................................ 7-2
Voltage Output Derivative Gain .................................................... 7-2
Voltage Output Actual ................................................................... 7-3
Voltage Output Zero...................................................................... 7-3
Voltage Output Span..................................................................... 7-3
Current Input Rating...................................................................... 7-3
Current Input Limit ........................................................................ 7-3
Current Input High Fault................................................................ 7-3
Current Input High Fault Retry Number ........................................ 7-3
Current Input High Fault Retry Time ............................................. 7-3
Current Input Overload Fault ........................................................ 7-3
Current Input Overload Time ........................................................ 7-3
Current Input Actual ...................................................................... 7-4
Current Input Zero......................................................................... 7-4
Current Input Span........................................................................ 7-4
Current Input Threshold Load Failure ........................................... 7-4
Current Output Rating................................................................... 7-4
Current Output Limit...................................................................... 7-4
Current Output Setpoint ................................................................ 7-4
Current Output Proportional Gain ................................................. 7-4
Current Output Integral Gain......................................................... 7-4
Current Output Derivative Gain..................................................... 7-4
Current Output Actual ................................................................... 7-4
Current Output Zero...................................................................... 7-5
Current Output Span..................................................................... 7-5
KVA Input Rating .......................................................................... 7-5
KVA Input...................................................................................... 7-5
Power Output Rating..................................................................... 7-5
Power Output Limit ....................................................................... 7-5
Power Output Setpoint.................................................................. 7-5
Power Output Proportional Gain ................................................... 7-5
Power Output Integral Gain .......................................................... 7-5
Power Output Derivative Gain ...................................................... 7-6
Power Output ................................................................................ 7-6
Power Factor ................................................................................ 7-6
Duty Cycle Output......................................................................... 7-6
iii
Duty Cycle Setpoint ...................................................................... 7-6
Local Digital Control Display Selection ......................................... 7-6
Local Digital Control Setpoint........................................................ 7-6
Local Analog Setpoint ................................................................... 7-6
Analog Setpoint Zero .................................................................... 7-6
Analog Setpoint Span ................................................................... 7-7
Analog Output Selection ............................................................... 7-7
Analog Output ............................................................................... 7-7
Analog Output Bias ....................................................................... 7-7
Analog Output Span...................................................................... 7-7
Control Word................................................................................. 7-8
Status Word .................................................................................. 7-9
Ramp Up Time.............................................................................. 7-9
Ramp Down Time ......................................................................... 7-9
Configuration Word ..................................................................... 7-10
Control Strategy Selection .......................................................... 7-10
Magnetizing Sequence Calibration ............................................. 7-10
Repetitive Pulse Calibration........................................................ 7-10
Load Type Selection ................................................................... 7-10
Product Type .............................................................................. 7-10
Serial Number ............................................................................. 7-11
Control Power Time On .............................................................. 7-11
Output Time On .......................................................................... 7-11
KW-Hour ..................................................................................... 7-11
Software Version......................................................................... 7-11
Network Loss .............................................................................. 7-11
Network Address......................................................................... 7-11
Network Baud Rate..................................................................... 7-11
MODBUS Address ...................................................................... 7-11
MODBUS Baud Rate .................................................................. 7-12
Network Type.............................................................................. 7-12
Fault Code .................................................................................. 7-12
Fault Index .................................................................................. 7-12
Fault Buffer #1 ............................................................................ 7-12
Fault Buffer #2 ............................................................................ 7-12
Fault Buffer #3 ............................................................................ 7-12
Fault Buffer #4 ............................................................................ 7-12
Fault Buffer #5 ............................................................................ 7-12
iv
Fault Buffer #6 ............................................................................ 7-12
Fault Buffer #7 ............................................................................ 7-13
Fault Buffer #8 ............................................................................ 7-13
Chapter 8........................................................................................8-1
Troubleshooting .............................................................................. 8-1
Control PCB LED Indicators ......................................................... 8-2
Local Digital Control Option LED Indicators.................................. 8-3
Fault and Alarm Codes ................................................................. 8-3
Fault Reset ................................................................................... 8-6
Fault Buffer ................................................................................... 8-6
Troubleshooting Guide.................................................................. 8-7
Appendix A ...................................................................................A-1
Mechanical Dimensions .................................................................. A-1
Appendix B ...................................................................................B-1
Electrical Drawings.......................................................................... B-1
Glossary.............................................................................................i
v
List of Figures
Figure 1-1 851 DSPC Schematic Diagram................................................................... 1-1

Figure 1-2 Phase-Angle Control Half Cycles................................................................ 1-2
Figure 1-3 Phase-Angle Duty Cycle Output ................................................................. 1-3
Figure 1-4 Zero-Crossover Control ..............................................................................1-4
Figure 1-5 Zero-Crossover Current Input Limit............................................................. 1-5
Figure 1-6 Zero-Crossover Control Magnetizing Sequence ......................................... 1-6
Figure 1-7 Zero-Crossover Control Repetitive Pulse.................................................... 1-6
Figure 2-1 Mounting Dimensions ................................................................................. 2-2
Figure 2-2 Cover screw locations ................................................................................. 2-3
Figure 2-3 Input & Output Power Lug locations (200A unit) ......................................... 2-3
Figure 2-4 Input & Output Power Lug locations (50A unit) ........................................... 2-4
Figure 2-5 Remote Feedback Terminal........................................................................ 2-5
Figure 2-6 Control Connectors .....................................................................................2-6
Figure 2-7 Typical Control Connections ....................................................................... 2-7
Figure 2-8 Digital Input Schematic ............................................................................... 2-8
Figure 2-9 Analog Input Schematic ............................................................................ 2-10
Figure 2-10 Analog Output Schematic ....................................................................... 2-11
Figure 3-1 Control PCB LED Location..........................................................................3-1
Figure 3-2 Print Preview Window .................................................................................3-9
Figure 3-3 Configuration Tool..................................................................................... 3-11
Figure 3-4 Ratings & Limits Tab................................................................................. 3-12
Figure 3-5 Control Configuration Tab ......................................................................... 3-13
Figure 3-6 Fault Setup Tab ........................................................................................3-14
Figure 3-7 PID Setup Tab .......................................................................................... 3-15
Figure 3-8 Network Tab.............................................................................................. 3-16
Figure 3-9 Configuration Tool On-Line ....................................................................... 3-18
Figure 3-10 Monitor Window ...................................................................................... 3-23
Figure 3-11 Fault History............................................................................................3-25
Figure 3-12 Flash Programming................................................................................. 3-26
Figure 4-1 Calibration................................................................................................... 4-1
Figure 4-2 Remote Feedback.......................................................................................4-4
Figure 4-3 Manual Calibration Window ...................................................................... 4-13
Figure 5-1 Local Digital Control Panel.......................................................................... 5-1
Figure 6-1 A 9 Pin to 9 Pin Null Modem Cable Diagram .............................................. 6-1
Figure 6-2 A 25 Pin to 9 Pin Null Modem Cable Diagram ............................................ 6-1
Figure 8-1 Main Control PCB LED indicator location.................................................... 8-2
Figure 8-2 Local Digital Control....................................................................................8-3
Figure A-1 50A Model ..................................................................................................A-1
Figure A-2 100A Model ................................................................................................A-2
Figure A-3 200A Model ................................................................................................A-3
Figure B-1 Electrical Schematic ...................................................................................B-3
Figure B-2 - 50A Model ................................................................................................B-4
Figure B-3 - 100A Model ..............................................................................................B-5
Figure B-4 - 200A Model ..............................................................................................B-6
vi
List of Tables
Table 1-1 Technical Specifications...............................................................................1-9
Table 2-1 Wiring Information ........................................................................................ 2-4
Table 2-2 Digital Interface Plug ....................................... Error! Bookmark not defined.
Table 2-3 Relay Contact Ratings ................................................................................. 2-9
Table 2-4 Analog Interface Plug...................................... Error! Bookmark not defined.
Table 3-1 Status Lamp Description ............................................................................ 3-19
Table 5-1 Display Selections........................................................................................ 5-2
Table 5-2 Digital Control Status ................................................................................... 5-3
Table 5-3 Pushbutton function in Normal mode, Local Digital Control ......................... 5-4
Table 5-4 Pushbutton function in Normal mode, Local Analog Control ........................ 5-5
Table 5-5 Pushbutton function in Normal mode, Remote Control ................................ 5-6
Table 5-6 Pushbutton function in Display Select Mode, Local Control ......................... 5-7
Table 5-7 Pushbutton function in Display Select Mode, Remote Control ..................... 5-8
Table 6-1 Serial Port Configuration .............................................................................. 6-2
Table 6-2 MODBUS RTU Query (from Master) ............................................................ 6-3
Table 6-3 MODBUS RTU Read Response (from 851) ................................................. 6-4
Table 6-4 MODBUS RTU Write Response (from 851) ................................................. 6-4
Table 6-5 MODBUS RTU Exception Response (from 851).......................................... 6-5
Table 6-6 MODBUS RTU Exception Codes ................................................................. 6-5
Table 7-1 List of Settings.............................................................................................. 7-1
Table 8-1 Control PCB LED Indicators......................................................................... 8-2
Table 8-2 Local Digital Control LED Indicators............................................................. 8-3
Table 8-3 Fault and Alarm Codes ................................................................................ 8-4
Table 8-4 Troubleshooting Guide.................................................................................8-8
vii
Chapter 1
Product Description
The 851 Digital SCR Power Controller offers the latest in Digital Signal Processing (DSP) technology and
software. The 851 is designed for a single-phase application. The 851 uses an advanced, dsp-based
firing circuit to control a single phase, two SCR AC Switch. The 851 is capable of firing into either direct
or transformer coupled loads. The basic circuit configuration is shown in the figure below.
Figure 1-1 851 DSPC Schematic Diagram
1-1
Product Description June 2008
Phase-Angle Control
In Phase-Angle control, the line is connected to the load for a portion of each half cycle. It is
disconnected from the load for the remainder of the half cycle. The period during which the load is
connected is varied in response to the control signal providing proportional control of power to the load. A
sample picture of Phase-Angle control is shown below.
Figure 1-2 Phase-Angle Control Half Cycles
1-2
June 2008 Product Description
Phase-Angle Control Method

The 851 controls its output based on regulation mode. The regulation modes are Open Loop, Voltage
Output, Current Output, and Power Output. Each mode regulates to within 1% of rated output. The
Current Input Limit is accomplished by comparing the Current Input to the Current Input Limit. If the
Current Input exceeds the Current Input Limit the Current Output setpoint is lowered, which in turn will
lower the Current Input. A flow diagram of the control is shown below.
Figure 1-3 Phase-Angle Duty Cycle Output
RFI
Phase-Angle control can generate Radio Frequency Interference (RFI). This may, depending upon the
installation and magnitude, affect other electronic equipment (computers, telephones, etc.). Where RFI
may be a problem, Zero-Crossover control can be used for many of the electric heating applications. The
source inductance, load inductance, and circuit impedances determine the amount of RFI generated by
Phase-Angle control. Additional components may be required to reduce or eliminate RFI, such as the
use of an isolation transformer between the line and the 851 or the addition of line filters.
1-3
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 851
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 851 has predefined the total number of cycles to be 100. Therefore, the cycles ON and the
cycles OFF must equal 100. This will allow the output to be set to 1% or 1 cycle out of a 100. A sample
picture of the Zero-Crossover control is shown below.
Figure 1-4 Zero-Crossover Control
Zero-Crossover Control Method

The Zero-Crossover control method is based on calculation. The actual voltage output, current output,
and power output are calculated every cycle and compared to each respective setpoint. The cycles
continue until the calculated feedback exceeds its respective setpoint and then the unit turns off after the
next cycle. This necessitates a minimum of two cycles or 2% output since the first cycle is used for
calculation and turn off does not occur until after the second cycle.
1-4
Zero-Crossover Current Input Limit

The Zero-Crossover control method controls cycles and can only control Current Input by applying
Phase-Angle control to the individual cycles. The Phase-Angle control of the individual cycles will limit
the input current, and since the Zero-Crossover control is adaptive, the number of cycles will
automatically increase based on the voltage output, current output, and power output setpoints. The
Phase-Angle control of individual cycles does eliminate some of the features of the Zero-Crossover
control such as high power factor and low RFI. However, it does protect the load by limiting the current
that in some cases would be more important than the Zero-Crossover features. A sample picture of the
Zero-Crossover control with Current Input Limit is shown below.
Figure 1-5 Zero-Crossover Current Input Limit
Heating Loads
Resistance type heating loads fall into two general categories. The first category consists of heating
elements made from materials that exhibit relatively constant resistance whether hot or cold. These
include such elements as nichrome, calrod, chromolox and various steels. No particular precautions
need be taken in using such materials. The second category consists of elements made from materials
that exhibit low initial (cold) resistance such as tungsten, molybdenum, platinum, moly-disilicide, silicon
carbide (which ages) and quartz infrared lamps. Such elements require the use of the current limit option
that prevents more than a preset value of current from flowing during the initial low resistance condition of
the elements.
Zero-Crossover Load Type

The very nature of Zero-Crossover control, firing full cycles of power, tends to cause large inrush currents
into the load. This is especially true when transformers are connected to the output. This is because
transformers rely on their magnetic field to limit the current, which is present only after current has been
flowing for a short time. In order to eliminate this problem from happening, the Load Type setting can be
set for Direct Coupled or Transformer Coupled loads.
1-5
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 851 is first turned on. A sample picture of the Zero-Crossover
control magnetizing sequence is shown below.
Figure 1-6 Zero-Crossover Control Magnetizing Sequence
Repetitive Pulse
After the cycle has started, the Repetitive Pulse causes only the first cycle to start in Phase-Angle
control again in order to limit the current inrush. A sample picture of the Zero-Crossover control
Repetitive Pulse is shown below.
Figure 1-7 Zero-Crossover Control Repetitive Pulse
1-6
Standard Features
The 850 Series digital product family offers the following features:
• Flexibility. Configurable operating modes, ratings, limits, external inputs, and setpoints.
• On-Board Diagnostics. Fault memory (the last eight faults are available in fault buffer storage)
allows the user to record problems and, through the use of a computer, observe trends that could
indicate a need for process modification, troubleshooting or preventative maintenance.
• Computerized Setup and Calibration. RS-232 serial Configuration Tool for setup, digital calibration
and diagnostics
• Touch-Proof Mechanical Design prevents unintentional contact with hazardous voltage
• Advanced Process and Fault Monitoring. Real-time monitor of voltage, current, power and fault
conditions. Real-time adjustment of the setpoint. Changes can be made any of four different ways:
Locally, using an analog control signal.

Locally, using the Configuration Tool software.
Locally, with optional Local Digital Control feature.
Remotely, with optional Network Communications feature.
• Operates on universal line voltages, from 24 to 600 VAC and 50/60 Hz.
• DSP-based control
• 1600 Volt SCR's
• 20KHZ pulse transformer coupled SCR gating circuit
• 50KHZ digital firing control
• True RMS calculation of voltage, current, and power at 10KHZ sampling
• Simultaneous regulation of voltage, current, and power
• User-configurable analog input
• User-configurable analog output
• Non-volatile storage of all digital settings
• Support of MODBUS RTU protocol
• Support of multiple baud rates on the serial port
1-7
Optional Features
The following optional features are available for the 851:
• Network Interface, allowing for remote control and monitoring of the 851. 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 851. 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.
1-8
Technical Specifications
Table 1-1 Technical Specifications
Input Line Voltage 24 to 600 VAC RMS
Input Line Frequency 50/60 ± 2 HZ
Current Rating 50 to 600 A; higher ratings are available, consult factory
Short Circuit Current Rating 50 Hz 60 Hz
50/100A - 1,273ARMS 50/100A - 1,336ARMS
200A - 3,111ARMS 200A - 3,267ARMS
600A - 8,839ARMS 600A - 9,281ARMS
Fuse I2t Rating 50 Hz 60 Hz
50/100A - 16,200 A2sec 50/100A - 14,885 A2sec
200A - 96,800 A2sec 200A - 88,940 A2sec
600A - 781,250 A2sec 600A - 717,813 A2sec
Control Voltage 85 to 265 VAC
Control Power 50 VA
Analog Input 0 to 10 VDC or 0 to 20mA (250Ω)
Analog Output 0 to 5 VDC or 0 to 20mA (10V max)
Digital Input 0 to 5 VDC
Regulation 1%
Isolation to ground 2500 VAC
Ambient Temperature Range 0 to 50ºC
1-9
Floating Point Data and Current Range
Floating point data (data containing a decimal point) in the 851 are stored and transferred (serial,
network, etc. send and receive) as 16 bit integers. In order to preserve accuracy, the floating point value
is scaled (multiplied) by 10 before being sent. Likewise, floating point data received by the controller are
adjusted (divided) by a factor of 10. For example, a Voltage Setpoint equal to 208.7 Volts will be
transferred as 2087.
In order to accommodate high numeric values for current and power in the 851, the concept of a Current
Range has been implemented.
The low current range is selected by resetting bit 11 of the Configuration Word setting (#97). With the
low current range selected, the current range is 0 – 1,000 Amps. The accuracy of current and power
values is .1 unit (.1Amp), (.1KW), (.1KVA). Floating point values related to current and power are scaled
by a factor of 10 (x10) before transfer.
The high current range is selected by setting bit 11 of the Configuration Word setting (#97). With the
high current range selected, the current range is 0 – 10,000 Amps. The accuracy of current and power
values is 1 whole unit (1Amp), (1KW), (1KVA); there is no scaling of floating point values related to
current or power.
For example, if the unit is configured for high current, and the Current Setpoint is 209 Amps, it will be
transferred as 209. Note that only current and power values are affected by the Current Range selection.
The Voltage Setpoint referenced above would continue to be transferred as 2087.
Part Number
The Part Number format for the 851 is described below.
851 AAAA 00 00
Product Options:
Current Rating: Dx - DeviceNet™
50A Px - Profibus Reserved
Product Series
100A Ex - Ethernet for future use.
200A x1 - Local Control
x2 - Remote Control
1-10
Chapter 2
Hardware
Installation
Prior to installation, the 851 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 851 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 851 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 851 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 851 is rated at 50°C maximum ambient temperature. If the 851 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.
Vibration
If the mounting site has a vibration concern, the 851 should be mounted using industry standard shock
mounting techniques.
2-1
Hardware June 2008
Mounting
The 851 is intended to be mounted in a vertical position, and is provided with mounting flanges on both
sides of the unit. Each flange has 5/16” diameter holes at the top, and 5/16″ slots on the bottom.
Suitable mounting hardware would consist of a 1/4" bolt, a flat washer, and a lock washer in each of the
four mounting holes.
Allow four inches on each side and a minimum of four inches above and below the 851 for adequate
cooling. It is recommended that the enclosure exhaust vents be located above the top of the heatsink.
Allow additional room for wiring as required by the individual application.
Figure 2-1 Mounting Dimensions
Disconnect Means
It is required that a circuit breaker, fused disconnect or fuses be installed upstream of the 851 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 50A unit, 150A for the 100A unit, and 250A for the 200A 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 851.
It is up to the discretion of the installer to allow access room to service the unit.
2-2
June 2008 Hardware
The Phillips head cover screws are

located at the four corners of the unit,
and are removed to open the covers on
their inside hinges, providing access to
the power wiring terminals.
Figure 2-2 Cover screw locations
The input power lugs are located under the top cover. The output power lugs, the remote feedback
terminal block, and the chassis ground lug are located under the bottom cover as shown in the following 2
figures.
Figure 2-3 Input & Output Power Lug locations (200A unit)
2-3
Figure 2-4 Input & Output Power Lug locations (50A unit)
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.
Table 2-1 Wiring Information
Unit size Power Lugs Ground Lug Feedback Terminal
Wire Range Screw Head Wire Range Screw Wire Range Screw
Head Head
50A 14-2 [8*] AWG Slotted 14-2 [8*] AWG Slotted 8-24 [14*] AWG Slotted
100A 14-1/0 [2*] AWG Slotted 14-1/0 [8*] AWG Slotted 8-24 [14*] AWG Slotted
200A 6-3/0 [2/0*] AWG ¼ inch hex 14-1/0 [4*] AWG Slotted 8-24 [14*] AWG Slotted
Note: Size in brackets [*] is recommended for 90ºC wire insulation.
2-4
June 2008 Hardware
Remote Feedback Wiring
If remote feedback is used, the connections are

made to the Remote Feedback Terminal. Current
feedback is connected to terminals 1 (+) and 2
(common), and voltage feedback is connected to
terminals 3 (X1) and 4 (X2).
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.
The current feedback signal should be about 2.5

Vrms at the rated output current, and the voltage
feedback signal should be in the same range as the
input voltage. Allowable ranges are 300-600V, 150-
300V, 75-150V, 37.5-75V and 24-37.5V.
Figure 2-5 Remote Feedback Terminal
2-5
Control Connections
Control connections are made using the pluggable

terminal blocks that are located on the right side of
the 851. These terminals accept fine stranded wire
up to 12 AWG.
The 851 requires 85-265VAC 50/60Hz @ 50VA

control power for the circuit boards and cooling
fans. This must be wired to the two-position plug
labeled Control Power.
Figure 2-6 Control Connectors
2-6
June 2008 Hardware
The following figure shows a typical wiring diagram for control connections.
Figure 2-7 Typical Control Connections
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.
2-7
Digital Interface
The digital interface consists of the nine-position plug labeled Digital Interface. The following table
describes each terminal and its default operation. Terminals 1, 3, and 5 provide 15 volts through a 470 Ω
resistor in order to develop a 10 volt, 10 mA signal into the appropriate digital input. A typical schematic
of the digital inputs follows the table.
Table 2-2 Digital Interface Plug
Terminal Terminal description Standard operation.

Number
1 External Fault power Shorting 1 to 2 provides a external fault input.

Open indicates no remote fault.
2 External Fault input
3 Remote/local power Shorting 3 to 4 puts the unit into remote

mode. Open defaults to local mode.
4 Remote/local input
5 Enable power Shorting 5 to 6 enables the unit.
6 Enable input Open inhibits operation.
7 Fault common Fault relay common connection.
8 Fault NC Contact opens when a fault occurs.
9 Fault NO Contact closes when a fault occurs.
Note: Bit 2 of the Configuration word is used to select Normally Open (NO) or Normally Closed
(NC) switch operation for the external fault. The default setting is (NO).
Figure 2-8 Digital Input Schematic
2-8
June 2008 Hardware
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.
External Fault Input

One typical use for the External Fault Input would be the micro switch on an external semiconductor
fuse. The default state is for a normally open switch to indicate a “normal” condition. It may be
programmed by the user for a normally closed switch to indicate a “normal” condition.
Remote/Local Input
The Remote/Local Input is used to select the control mode. Remote control is selected to allow control
from the network (when present). The default state (open) is for local control.
Enable Input
The Enable Input is used to provide a local enable/inhibit function. The default state (open) inhibits the
unit (prevents the SCR from firing).
Digital Outputs
The digital outputs (Fault – Common, NC, and NO) are relay contacts from a miniature relay on the digital
control printed circuit board. It is very important to not exceed the contact ratings listed in the table below.
Table 2-3 Relay Contact Ratings
Load Type Voltage Current
Resistive 125VAC 0.30A
Resistive 30VDC 1.0A
Inductive 125VAC 0.20A
Inductive 30VDC 0.50A
A pilot relay can be used to interface to larger relays or contactors if required.
2-9
Analog Interface
The analog interface consists of the five-position plug labeled Analog Interface. The following table
describes each terminal and its default operation.
Table 2-4 Analog Interface Plug
Terminal Terminal description Standard operation.

Number
1 Analog supply Connecting a 10k potentiometer with JP2

OFF provides a local analog control. See
2 Analog input Figure 2-9.
3 Analog ground
4 Analog output Provides a configurable analog output of 0-5

volts (JP1 on) or a mA output (JP1 off).
5 Analog ground
Analog Input
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 10VDC 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. 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 Analog Setpoint
Zero calibration to offset the 4mA input to be 0% setpoint. Also, other voltages and currents less than
10VDC and 20mA are acceptable by utilizing the Analog Setpoint Span calibration to set 100% setpoint.
The Analog Input Circuit. If a mA

input signal is desired, Jumper JP2 is
inserted to connect the 249 ohm
burden resistor. If a 0-5 volt or a 0-10
volt signal is desired, connect the
signal source between terminal 2 (+)
and 3(-).
Figure 2-9 Analog Input Schematic
2-10
June 2008 Hardware
Analog Output
The analog output (Analog Output) is designed to be a current or voltage output. The Analog Output
Selection defines what internal signal is connected to the 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, short
JP1, 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 Analog Output Bias and the
Analog Output Span.
The Analog Output Circuit. If a 5 volt

output signal is desired, Jumper JP1
is inserted to connect the 249 ohm
burden resistor. If a 10 volt signal is
desired, an external 500 ohm resistor
should be connected across the
output terminals.
Figure 2-10 Analog Output Schematic
Remote Feedback
It is standard for the output voltage and current to be sensed internally. The 851 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 851. 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 851. 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 200A to 5A is used on a 200A 851
unit, the burden resistor would be 2.5V/5A or 0.8 ohms.
Over-temperature Sensing
A temperature sensor is mounted on the heatsink of the 851 to detect and indicate an over temperature
condition. The standard temperature sensor is supplied with contacts that are normally closed (NC).
2-11
2-12
Chapter 3
Configuration
Startup
Once the 851 is mounted, and the wiring is in place, apply control power to the unit. It is not necessary
for main power to be applied at this time.
DANGER
This equipment is at line voltage when AC power is connected. Disconnect and lock out all
ungrounded conductors of the AC power line. Failure to observe these precautions could
result in severe bodily injury or loss of life.
When control power is applied,

check the LED’s on the control
board to verify that the power
supplies are on and the DSP is
operating. At this time the red
FAULT LED will be on, the three
green power supply status LED’s
will be on, and the HEARTBEAT
LED will be blinking at about a 1
second rate.
Figure 3-1 Control PCB LED Location
With control power applied and status lights operating properly, the unit is ready for configuration.
Configuration 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 will be made at the user site.
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. Spang offers a null modem cable (P/N 835472005) and a USB
to Serial Converter (P/N 835472000) to use with the 851.
WARNING
product life. Wiring or application errors, incorrect or inadequate AC supply, or excessive
ambient temperature may result in malfunction of the system.
3-1
Configuration June 2008
Configuration Tool Installation
The 851 Configuration Tool is a serial configuration/monitoring tool that runs on a Windows-based PC.
The minimum system requirements are:
Windows 98 or higher,
64MB ram,
10MB hard disk space,
an available serial port (can use USB to serial converter)
The 851 Configuration Tool allows off-line editing and storage of configuration files. The Configuration
Tool also allows on-line, real-time changes to the 851 settings through the serial port. The capabilities of
the Configuration Tool include: on-line configuration, setpoint changes, operation, monitoring, calibration,
and file storage and retrieval.
The Configuration Tool is delivered on CD-Rom and includes ‘auto-run’ capability. However, should the
CD NOT run automatically once inserted into the cd-rom drive, browse for the cd-rom drive, and double-
click on the file ‘setup.exe’.
The Configuration Tool default install location is:
C:\Program Files\Spang Power Electronics\ 851 Configuration Tool vxxx
Once successfully installed, the Configuration Tool will be accessible via the Start Menu.
Note: The install process updates the computer’s system registry with the required
configuration information.
3-2
June 2008 Configuration
Running the Configuration Tool
Run the Configuration Tool from the start menu:
Start button -> Programs -> Spang Power Electronics -> 851 Configuration Tool vxxx
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 851. The
setting values have been read from a setup (.csv) file stored on the computer running the configuration
tool.
3-3
3-4
Configuration Tool Menu and Task Bar Descriptions
The 851 Configuration Tool menu bar is shown below, followed by a description of each option.
File Menu
File Menu including the ‘Save Calibration’ menu File Menu including the ‘Restore Calibration’ menu
choice. choice.
The ‘Save Calibration’ menu choice is visible only The ‘Restore Calibration’ menu choice is visible
under certain conditions, and should be used only only under certain conditions, and should be used
by authorized service personnel. only by authorized service personnel.
File Option Description
Open Open a standard dialog box listing the configuration files available for loading and
editing. (Configuration files are of the form <filename>.csv) and are read from
and saved to the host system.
Save Save and close changes made to the configuration file.
Print Open the Print Preview window; display 851 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 851 eeprom.
Restore Restore calibration values from factory defaults stored in 851 eeprom.
Calibration
Exit Close the Configuration Tool
3-5
Com Setup Menu
Com Options Description
Com1
Com2
Com3
Com4 The Com Setup menu is used to select the serial port on the host computer
Com5 available for use with the 851.
Com6
Com7
Com8
Window Menu
Window Options Description
Settings Open the Settings Pane. (This is the default upon program entry).
Monitor Establish on-line communication and open the Monitor pane to view 851
operation.
Calibration Establish on-line communication and open the Calibrate pane.
Fault History Open the Fault History window (useful only if on-line).
Flash Open the Flash Programming window. Intended for use by authorized service
Programming personnel only.
3-6
Help Menu
Help Options Description
Manual Open (in a separate browser window) this product manual in pdf format.
About Display the version number of the Configuration Tool software.
3-7
Taskbar
The Configuration Tool Taskbar provides shortcuts to frequently used options.
Taskbar Description
Items
Open Folder Same as the File->Open menu option
Floppy Same as the File->Save menu option.
Printer Same as the File->Print menu option.
Monitor Same as the Window->Monitor menu option.
Calibrate Same as the Window->Calibrate menu option.
Settings This button appears on the taskbar if either the Monitor or Calibration window is
visible. Same as the Window->Settings menu option.
Fault Same as the Window->Fault History menu option.
Offline/Online Toggle between Off-line programming and On-line communication with the 851.
The caption and color of the button indicate the current status of communication
between the configuration tool and the 851.
A Red button with an Offline caption indicates No Communication between the

Configuration Tool and the 851.
A Yellow button with an Online caption indicates one of two possibilities: the
851 is under Remote (network) Read Only control; or the 851 is under Analog
(vs Digital) control).
A Green button with an Online caption indicates Read/Write local

communication between the Configuration Tool and 851.
3-8
Print Preview
The File->Print menu selection, or the printer icon on the Taskbar, opens the Print Preview window.
The Print Preview window displays a tabular summary of the settings stored in the Configuration Tool.
Figure 3-2 Print Preview Window
Click [Print] to send a copy of the table to the printer port of the host computer.
Click [Close] to exit the Print Preview window.
3-9
Off-line Programming
Off-line programming allows the user to edit 851 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 851default.csv file
(included with the configuration tool).
Load/Save the Configuration File

To load a configuration file from the host computer to the Configuration Tool,
● Select the File->Open menu option, (or click the file folder icon on the Taskbar)
● Browse the files in the ‘file open’ dialog, and select the desired configuration (*.csv) file.
The settings as defined in the configuration file are loaded into the Configuration Tool, and can be viewed
and/or modified.
To save settings to a .csv file on the host computer,
● Select the File->Save menu option, (or click the floppy icon on the Taskbar)
● Specify <filename>.csv .
The settings currently in the Configuration Tool are written to the specified file on the host computer.
3-10
Configuration Tool Settings Windows

The 851 Configuration Tool window is shown below.
Figure 3-3 Configuration Tool
The left pane is used for general status and control information related to the 851. In Off-line mode, only
control information is visible in the left-hand pane:
‘Regulation Mode’ is a drop-down box containing the regulation choices.
‘Local Control’ is a button that toggles between Local Analog and Digital control.
On start up, the right-hand side of the window displays the Settings pane, 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
Ratings and Limits Tab
The Ratings and Limits Tab holds the settings for
Voltage Input Rating Current Input Rating
*Voltage Output Rating Current Output Rating
Voltage Output Limit Current Input Limit
*Voltage Output PT Secondary Current Output Limit
Power Output Rating - Read Only Frequency Rating
Power Output Limit Ramp Up Time
KVA Input Rating – Read Only Ramp Down Time
Current Range
* For a direct-coupled load (Load Type) the Voltage Output Rating and the Voltage Output PT
Secondary are Read Only and follow the Voltage Input Rating.
Figure 3-4 Ratings & Limits Tab
3-12
Control Configuration Tab
The Control Configuration Tab holds settings for
Thermostat NC/NO Select Control Strategy
External Fault NC/NO Select Load Type
Auto Start on Powerup Enable/Disable * Magnetizing Sequence
Low Voltage Fault/Alarm Selection * Repetitive Pulse
Analog Output Selection
Local Digital Display Selection
* Only used for Zero Crossover with transformer coupled load applications.
Figure 3-5 Control Configuration Tab
White fields indicate Read/Write
Cyan fields indicate Read Only information
3-13
Fault Setup Tab
The Fault Setup Tab holds the settings for:
Voltage Input High Current Input Overload
Voltage Input Low Current Input Overload Time
Current Input High Current Input Threshold Load Failure
Current Input High Retry Number
Current Input High Retry Time
Figure 3-6 Fault Setup Tab
3-14
PID Setup Tab
The PID Setup Tab holds the PID settings for
Power Output Voltage Output Current Output
Proportional Gain Proportional Gain Proportional Gain
Integral Gain Integral Gain Integral Gain
Derivative Gain Derivative Gain Derivative Gain
Figure 3-7 PID Setup Tab
3-15
Network Tab
The Network Tab holds settings for
Network Type MODBUS Address
Network Baud Rate MODBUS Baud Rate
Network Address Network Loss Option
Software Version
Serial Number
Figure 3-8 Network Tab
3-16
On-line Programming
On-line programming involves actual serial communication between the configuration tool and the 851.
Settings are read from and written to the 851 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 851.
To establish on-line communication between the Configuration Tool and the 851 unit,
● Connect a standard, 9-pin null modem cable from the serial port of the host computer to the serial
port of the 851
● Assign the correct comm port to the configuration tool
● Click [Online/Offline] on the taskbar
If any settings have been modified using the configuration tool offline, the following message will appear:
If settings have been modified offline, either

individually or by loading a .csv file, the user
has the option of transferring, or writing, the
settings stored in the 851 Configuration Tool to
the 851. If no modifications have been made,
the prompt will not appear.
Click Yes to write settings from the tool to the 851; click No if settings are NOT to be written to the 851.
Depending on the response, the configuration tool will either write its settings to the 851 and then read
them all back, or will read all settings from the 851 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 851 (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].
3-17
When the Configuration Tool is communicating on-line with the 851, status, control and setting
information is continuously read from the 851 and refreshed in the Configuration Tool. Additional status
and control information is visible in the left-hand pane.
It is not necessary to be On-line to review and change the settings – but it is necessary to be On-line to
write the changes to the unit. It is also necessary for the Remote/Local switch to be in the Local position
for the Configuration Tool to allow on-line changes to the settings.
Figure 3-9 Configuration Tool On-Line
3-18
Status indicators are described in the table below:
Table 3-1 Status Lamp Description
Lamp Color Description
Enable input Green The 851 is Enabled
Red The 851 is Inhibited
Output Status Green Output is ON
Red Output is OFF
Remote/Local input Green Local control is active
Red Remote (network) control is active
On/Off button Toggles the 851 output
Alert indicator Flashing Indicates an Alarm Condition (described in

Yellow the message box below the lamps)
Flashing Indicates a Fault Condition is present

Red (described in the lower message box)
Note: During normal operation, message

reads: No detected faults or alarms
Fault Reset button Click to send a ‘Fault Reset’ to the 851. The
851 will attempt to recover from the alert
condition. If recovery is accomplished, normal
operation will resume.
On-Line Navigation and Changes

To edit settings:
• Press [Tab] or [Enter] to move forward and select a setting

• Press [Shift+Tab] to move backward and select a setting
• Double-click the mouse over a setting to select it
• Once selected, enter the desired setting value or click a choice from the drop down list
• Press [Tab], [Enter] or click outside setting
• Press [Escape] to cancel.
When a change is made to a setting, the following prompt appears:
3-19
A Yes response to the message prompts the Configuration Tool to write the setting to the 851. If
unsuccessful, an error message may appear, and the setting reverts to its previous value.
Factors Affecting Write Capability

Write capability from the configuration tool to the 851 is affected by several factors:
No writes are accepted from the configuration tool to the 851 if the Remote/Local input is in Remote.
The 851 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 851. If the 851 is
operating under Local Analog control, setpoints cannot be written from the Configuration Tool to the 851.
The following prompt will appear:
In order to write a setpoint from the

Configuration Tool to the 851, the unit must be
under Local Digital control.
3-20
The 851 settings related to actual 851 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 851 output is off.
Voltage Output Span and Current Output Span can be written only when the 851 output is on.
When a setting cannot be written the following message appears:
Refer to the Settings Chapter for programming factors specific to each setting.
3-21
On-line Monitor
The Monitor mode provides a real-time view of 851 operation. Each setting in the Monitor pane is
updated approximately every 2 seconds.
To access the on-line Monitor mode, select the WindowÆMonitor menu item, or click [Monitor] on the
Taskbar.
3-22
The Monitor Window includes the following data
Duty Cycle Setpoint Current Output
Duty Cycle Output Analog Input
Power Output Setpoint KVA Input
Power Output Power Factor
Voltage Input Frequency Actual
Voltage Output Setpoint KiloWatt Hours
Voltage Output Control Power Time On
Current Input Output Time On
Current Output Setpoint
The [Zero] button, when clicked, sets the accumulated time to zero.
Figure 3-10 Monitor Window
3-23
Green field indicates regulation mode
The operating setpoint for each of the regulation modes is shown in the middle column. The setpoint
associated with the selected regulation mode is displayed with a green background.
To change a setpoint:
● Select the setpoint to change and enter the desired value
● Press [Enter] or click outside the field to write the new setpoint.
• Setpoints can be modified only under Local DIGITAL control.

• Modified setpoints are italicized until written to the 851.
• Press the [Escape] key to cancel.
• The Duty Cycle Setpoint cannot be written unless Open Loop regulation mode is
selected.
• The setpoint associated with the selected regulation mode is the control setpoint. The
other setpoints become operating limits of their respective control loops.
3-24
Fault History
The fault history lists the last eight faults recorded by the 851. The information is read from the 851 and
displayed in tabular form.
To access the on-line Fault History mode, select the Fault History menu item, or click [Fault] on the
Taskbar.
Figure 3-11 Fault History
Included in the Fault History table is the fault code, a description, and time (in hours) of the fault.
Click the [Print] button to send a copy of the information to the printer port of the host computer.
Click the [Close] button to close the Fault History window and return to the previous window.
With JP3 installed, click the [Zero] button to clear the fault buffers.
3-25
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 851 flash memory. This will require
the 851 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 851 software.
Figure 3-12 Flash Programming
3-26
Loss of Communication
Momentary loss of communication between the Configuration Tool and 851 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.
3-27
3-28
Chapter 4
Calibration
Proper calibration of the 851 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 851. Changing the Voltage/Current
Ratings or the Analog Input/Output signal levels requires recalibration.
Figure 4-1 Calibration
4-1
Calibration June 2008
The [Cal Enable] button must be clicked to enable calibration of voltage and current measurements.
Voltage Calibration
Voltage Input Span
Voltage Output Zero Voltage Output 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.
Current Calibration
Current Input Zero Current Input Span
Current Output Zero Current Output Span
Analog Input/Output Calibration
Analog Setpoint Zero Analog Setpoint Span
Analog Output Bias Analog Output Span
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
4-2
June 2008 Calibration
Current Rating
The current feedback signal (at rated current) of the 851 must be between 1.25Vrms and 2.85Vrms. The
typical unit is setup for a current feedback signal level of 2.50Vrms using the burden resistor of the
current transformer. Standard units have the following burden resistors and feedback signals.
Unit Size CT Burden Resistor Feedback Signal
50A 1000:1 49.9Ω 2.50Vrms
100A 2000:1 49.9Ω 2.50Vrms
200A 3000:1 39.2Ω 2.61Vrms
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 50A unit to a 10A unit, the burden resistor should be changed
so that the current feedback signal will produce 2.5Vrms when the primary current is 10A. Since the
secondary current at 10A is 10/1000 = 10mA, the resistor should be:
2.5 / 10mA = 250Ω
The nearest standard value 1% resistor is 249Ω. The power in the resistor at rated current is (10mA)2 x
249 = 24.9mW, so a resistor with a power rating of 50mW or greater is required. A 1/4W or a 1/2W
resistor should be used so that it will properly fit in the connector (J10, terminals 1 and 4). The actual
voltage produced at rated current will be:
10/1000 x 249 = 2.49Vrms
Voltage Rating
The voltage feedback signal of a unit must be between 24Vrms and 600Vrms. The voltage sense circuit
automatically sets the hardware gain of the sensed voltage in the following ranges:
Voltage Rating
300 to 600
150 to 300
75 to 150
37.5 to 75
24 to 37.5
4-3
Remote Voltage and Current Feedback
The standard unit uses the same current feedback signal for both the input and output current. If an
output current transformer is used with the 851, the existing current feedback signals must be removed
and insulated before the remote current feedback signal can be connected to the Remote Feedback
Terminal provided on the 851. The internal voltage feedback signals must also be removed and insulated
before a remote voltage feedback can be connected to the Remote Feedback Terminal. The terminals
are shown below.
If remote feedback is used, the feedback

connections are made to the Remote
Feedback Terminal. The Current Output
feedback signal is connected to terminals 1
(+) and 2 (common), and Voltage Output
feedback signal is connected to terminals 3
(X1) and 4 (X2).
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.
The Current Output feedback signal should

be 2.5Vrms at the rated output current, and
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.
Figure 4-2 Remote Feedback
4-4
Calibration Procedure
WARNING
product life. Wiring or application errors, or improper calibration may result in malfunction
of the system.
To calibrate the 851, the unit must be connected to its rated input source, have control power on, and
have a load attached to the unit. The unit must be under local digital control. Open the Configuration
Tool and establish serial communication with the unit.
Click on the [Calibrate] button to open the 851 Calibration window. Click the [Cal Enable] button to
enable the function of the [Set] and [Zero] buttons for all but the analog input. [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.
4-5
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.
Note: If calibration is necessary because of the addition of remote monitoring, set the Load Type
to “Transformer-Coupled”, and calibrate the unit to the actual signals being measured.
The output voltage may be different from the input voltage, as may the current.
4-6
Saving Calibration
If desired, the new calibration may be saved in the 851 as the “Factory Default” calibration. The unit must
be on line, with the calibration window open. With control power turned on, install jumper JP3. JP3 is a
two-position jumper located immediately above connector J12 at the bottom of the control board.
From the File menu, select “Save Calibration”.
4-7
A dialog box will open asking if you want to replace the calibration defaults. Click [YES] to replace the
default calibration settings with the new calibration settings.
Remove the jumper (JP3), and the unit is ready for operation.
Restoring Factory Calibration
To recalibrate the unit using the stored calibration values, the unit must be on line, with the settings
window open. With control power turned on, install jumper JP3.
4-8
From the File menu, select “Restore Calibration”.
A dialog box will open asking if you want to restore calibration using the stored defaults. Click [YES] to
write the default calibration settings to the unit.
Remove the jumper (JP3), and the unit is ready for operation.
4-9
Analog Calibration
Analog signal settings are adjusted on-line in an iterative process to assure accurate signal readings and
optimal 851 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
Calibrate window.
If the analog input is derived from a 10K potentiometer, simply turn the pot full counterclockwise and
“zero” the input by clicking the 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 [Set] button with the mouse
pointer. Alternately, click the [Zero] button with the pot turned down, and the [Set] button with the pot
turned up until the readings are consistent (about 2 or 3 times).
If the analog input is a 4 – 20 mA signal, install jumper JP2 for 4 - 20 mA to terminals 2 and 3, set the
input to the minimum setting (4 mA) and select the [Zero] button. Then set the input to the maximum
setting (20 mA), enter 100 in the Gain Setting box, and click the [Set] button with the mouse pointer.
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.
4-10
To calibrate the analog output, set the analog output source to the analog setpoint. It allows a full range
of signal settings without having to actually power up the unit. Once calibrated, the analog output source
can 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 0-40A on a 50A unit, set the analog reference to 80 (this equals 40/50*100) to represent
maximum current output.
4-11
Check the Analog Output Enable box in the Calibrate window.
If the Analog Output is to be calibrated for a 0-5V output (as it may be for a typical digital meter), insert
jumper JP1 and 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 maximum and adjust the “gain”
slider until you obtain exactly 5 volts on the analog output (terminals 4 to 5 on the analog interface plug).
If the Analog Output is to be calibrated for a 4-20 mA signal, leave JP1 off and terminate the output into a
suitable burden (maybe a milli-ammeter). With the analog input set at zero, adjust the “bias” slider until
you read 4 mA on your meter. Then set the analog input for maximum, and adjust the “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.
4-12
Manual Calibration
WARNING
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 851 Configuration
Tool. To open the Manual Calibration window, insert jumper JP3, select Calibration in the Config Tool,
and press the [Manual] button. The Manual Calibration window is shown below:
Figure 4-3 Manual Calibration Window
Note the choices available for manual calibration:
Read from CSV File – open a .csv file stored on the host computer and read the calibration values.
Read from 851 Unit – read the current calibration values from the 851.
Calculate Defaults – Calculate new calibration values based on the voltage and current ratings.
Write to 851 Unit – Write all of the displayed calibration values to the 851.
Close the manual calibration window.
4-13
Magnetizing Sequence Calibration
Setting number 99 is the Magnetizing Sequence Calibration, which is used for zero-crossing control into a
transformer load.
The purpose of this setting is to soft start a transformer load when first powered up. The setting defines
the amount of phase control cycles which will occur during the first on cycle of zero-crossing control. A
minimum setting of 3 will usually keep the inrush current within acceptable limits. If the inrush current is
too high, increase the Magnetizing Sequence until the inrush current is within acceptable limits.
Repetitive Pulse Calibration
Setting number 100 is the Repetitive Pulse Calibration, which is used for zero-crossing control into a
transformer load.
The Repetitive Pulse represents a phase delay of the first on cycle during zero-crossing control. After the
cycle has started, the Repetitive Pulse causes only the first cycle to start in Phase-Angle control in order
to limit the current inrush. The setting is expressed as the percentage of the total cycle passed through to
the load.
In order to tune the Magnetizing Sequence and Repetitive Pulse, it is desirable to have some means of
observing the current. Using the Configuration Tool program, turn the unit on with a duty cycle of
between 10 and 50%. Start with the pulse setting at about 50%. If the inrush current is too high, adjust
the pulse setting either higher or lower until the inrush current is within acceptable limits.
4-14
Chapter 5
Local Digital Control Option

The Local Digital Control Option is an add-on display/control interface. It is used in one of two modes and
provides a four-digit numeric display, twelve LED’s and four pushbuttons that allow local control of the
851. The Local Digital Control Panel is shown below.
Figure 5-1 Local Digital Control Panel
Display and Status
The four-digit numeric display is used to display a selected setpoint or output. It is also used to indicate
alert conditions and special programming modes. There are four LED's to the right of the numeric
display, and two below it. The LED’s describe the information shown on the numeric display, and are
summarized in the following table:
5-1
Local Digital Control Option June 2008
Table 5-1 Display Selections
Setting #76
If this LED is lit Display Selection Description
equals …
Volts 1 Voltage Output (V) Voltage Output Actual in volts.

Output
Amperes 2 Current Output (A) Current Output Actual in amps.

Output
Kilowatts 3 Power Output (KW) Power Output in kilowatts

Output
Setpoint 4 Regulation Mode Voltage Setpoint, Current Setpoint

Volts, Amps, Setpoint (unit) or Power Setpoint in appropriate units
or Kilowatts
Volts 5 Voltage Output (%) Voltage Output Actual as % of rated

% of Rated voltage.
Output
Amps 6 Current Output (%) Current Output Actual as % of rated

% of Rated current.
Output
Kilowatts 7 Power Output (%) Power Output as % of rated power.

% of Rated
Output
Setpoint 8 Regulation Mode Voltage Setpoint, Current Setpoint

% of Rated Setpoint (%) or Power Setpoint as % of appropriate
Volts, Amps, rating
or Kilowatts
5-2
June 2008 Local Digital Control Option
The six status LED’s are summarized in the following table.
Table 5-2 Digital Control Status
LED Condition Description
Remote Status On The Remote/Local input is in the Remote state.
Off The Remote/Local input is in the Local state.
Enable Status On The Enable/Inhibit input is in the Enable state.
Off The Enable/Inhibit input is in the Inhibit state.
Analog Status On The Local mode is set to Analog, and the Remote/Local
input is in the Local state.
The Local mode is set to Digital, or the Remote/Local

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

Off input is in the Remote state.
On Status On The output is active.
Off The output is off.
Alert Status On Either a fault or alarm is present.
Off No detected fault or alarm.
Normal Mode Operation
Normal mode operation depends on two factors: the Remote/Local input, and the Analog/Digital control
status. If the unit is under Local Digital Control, the four pushbuttons are used to increment/decrement
the regulation mode setpoint, toggle the unit output, and toggle the control mode from digital to analog
(and vice-versa). Normal operation under Local Digital Control is summarized in the following table:
5-3
Table 5-3 Pushbutton function in Normal mode, Local Digital Control
Display Selection Up/Down Button Select Button On/Off/Reset Button
Voltage Output (V) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Setpoint in units; local Analog/Digital control
Increment/Decrement the
Regulation Mode Setpoint
Current Output (A) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Power Output (KW) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
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
Current Output (%) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
Power Output (%) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
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
Table 5-4 Pushbutton function in Normal mode, Local Analog Control
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
Power Output (KW) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
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
Power Output (%) Display the Regulation Mode Press and Hold to toggle Toggle the unit On/Off
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
If the unit is under Remote Control, the pushbuttons are inoperable, as summarized in the following
table.
Table 5-5 Pushbutton function in Normal mode, Remote Control
Voltage Output (V) No action No action No action
Current Output (A) No action No action No action
Power Output (KW) No action No action No action
Regulation Mode No action No action No action

Setpoint (units)
Voltage Output (%) No action No action No action
Current Output (%) No action No action No action
Power Output (%) No action No action No action
Regulation Mode No action No action No action

Setpoint (%)
5-6
Display Select Mode Operation
To enter Display Select mode, press the [SEL] pushbutton. Entry into the Display Select mode is
indicated by the characters ‘SEL’ in the four-digit numeric display. In this mode, the [Up Arrow] and
[Down Arrow] pushbuttons increment/decrement the Local Digital Control Display Selection. Display
Select mode operation is summarized in the following tables:
Table 5-6 Pushbutton function in Display Select Mode, Local Control
Voltage Output (V) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off;
display selection exit Display Select mode
Current Output (A) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off;
Power Output (KW) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off;
Regulation Mode Increment/Decrement the Exit Display Select mode Toggle the unit On/Off;
Setpoint (units) display selection exit Display Select mode
Voltage Output (%) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off;
Current Output (%) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off;
Power Output (%) Increment/Decrement the Exit Display Select mode Toggle the unit On/Off;
Regulation Mode Increment/Decrement the Exit Display Select mode Toggle the unit On/Off;
Setpoint (%) display selection exit Display Select mode
5-7
Table 5-7 Pushbutton function in Display Select Mode, Remote Control
Voltage Output (V) Increment/Decrement Exit Display Select mode Exit Display Select mode
the display selection
Current Output (A) Increment/Decrement Exit Display Select mode Exit Display Select mode
Power Output (KW) Increment/Decrement Exit Display Select mode Exit Display Select mode
Regulation Mode Increment/Decrement Exit Display Select mode Exit Display Select mode
Setpoint (units) the display selection
Voltage Output (%) Increment/Decrement Exit Display Select mode Exit Display Select mode
Current Output (%) Increment/Decrement Exit Display Select mode Exit Display Select mode
Power Output (%) Increment/Decrement Exit Display Select mode Exit Display Select mode
Regulation Mode Increment/Decrement Exit Display Select mode Exit Display Select mode
Setpoint (%) the display selection
5-8
Chapter 6
Serial Communication
Hardware
The serial port of the 851 is a standard, male, DB-9 connector. The hardware connection between a
standard PC COM port and the 851’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 A 9 Pin to 9 Pin Null Modem Cable Diagram
Figure 6-2 A 25 Pin to 9 Pin Null Modem Cable Diagram
6-1
Serial Communication June 2008
The setup of the serial port is described below.
Table 6-1 Serial Port Configuration
Baud Rate 4800, 9600, or 19200 baud
Parity None
Length 8 bits
Stop 2 bits
Handshake None
The default serial baud rate is 19200. The baud rate is accessible as setting #117, and can be modified
either with the 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 851 is cycled.
The Configuration Tool will detect baud rate automatically when on-line communication is established
with the 851.
6-2
June 2008 Serial Communication
Serial Protocol – MODBUS RTU
The MODBUS RTU protocol is a query/response or master/slave protocol. The 851 acts as a slave in the
MODBUS master/slave relationship. The MODBUS query and response are summarized in the following
tables.
Table 6-2 MODBUS RTU Query (from Master)
Byte Field Name Description
1 Slave Address 851 MODBUS address, from setting #116, or 0

for a broadcast message.
2 Function MODBUS function code, 3 (read) or 6 (write).
3 Address High Always 0
4 Address Low 851 setting number.
5 # Points High (read) Always 0 (read);

Data High (write) High byte of 16-bit value to be written (write).
6 # Points Low (read) Always 1 (read);

Data Low Low byte of 16-bit value to be written (write).
7,8 Error Check 16-bit CRC, low byte first
6-3
Table 6-3 MODBUS RTU Read Response (from 851)
1 Slave Address 851 MODBUS address, from setting #116.
2 Function MODBUS function code 3 (read).
3 Byte count Always 2
4 Data High High byte of 16-bit value read.
5 Data Low Low byte of 16-bit value read.
Table 6-4 MODBUS RTU Write Response (from 851)
2 Function MODBUS function code 6 (write).
3 Address High Always 0
4 Address Low 851 setting number.
5 Data High High byte of 16-bit value written (echo).
6 Data Low Low byte of 16-bit value written (echo).
6-4
June 2008 Serial Communication
When a message is received correctly (no communication errors, CRC checks out), but cannot be
executed, the 851 will generate an exception (error) response. No response is generated for a message
received incorrectly, or incompletely. No response is generated for broadcast messages.
Table 6-5 MODBUS RTU Exception Response (from 851)
2 Function MODBUS function code plus exception

indication (80 hex).
3 Exception code MODBUS exception code.
The 851 supports the following MODBUS exception codes:
Table 6-6 MODBUS RTU Exception Codes
Exception Code Description
01 Illegal function
02 Illegal data address (setting number).
03 Illegal data value.
Floating Point Data and Current Scaling
Floating point data (data containing a decimal point) are transferred as 16 bit integers. In order to
preserve accuracy, 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
Setpoint equal to 208.7 Volts will be transferred as 2087
An exception to floating point scaling occurs with the use of the High Current Range (bit 11,
Configuration Word). If the unit is configured for ‘Current Range 0 – 10,000Amps’, the accuracy of
current and power values is 1 whole unit (1Amp, 1KW, 1KVA). Such data is not scaled before transfer.
For example, if the unit is configured for ‘0 – 10,000 Amps’, and the Current Setpoint is 209 Amps, it will
be transferred as 209. Note that only current and power values are affected by the Current Range
selection. The Voltage Setpoint referenced above would continue to be transferred as 2087.
6-5
Additional Serial Information
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 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.
Error responses do not stop 851 operation.
Message bytes are sent and received as binary values, and not as ASCII characters.
Serial control of the unit is enabled when the Local/Remote switch is in LOCAL mode. 851’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.
6-6
Chapter 7
Settings
Caution
The 851 is configured using the programmable settings. Programming the settings
incorrectly can cause the 851 to exhibit intermittent or full output conditions.
The following table summarizes the settings of the 851. It is important to note that current scaling affects
the accuracy and limits of certain settings.
If the High Current Scale is selected (bit 11, setting #97), the accuracy of current settings is 1 Amp, the
minimum allowable value is 10x the minimum listed in the table, and the maximum allowable value is 10x
the listed maximum.
If the High Current Scale is selected, the accuracy of KVA and power settings is 1 KVA and 1 KW,
respectively. The minimum allowable value is 10x the minimum listed in the table, and the maximum
allowable value is 10x the listed maximum.
The settings that are affected by current scaling have a (Ix10) note.
Table 7-1 List of Settings
Setting No. Units Description
Voltage Input Rating

Vrms
Read/Write The input rating of the voltage supplied to the
1 Min: 0.0
Condition: Off 851.
Max: 600.0
Default: 480.0V
Voltage Input High Fault The level compared to Vinrms that causes a
Read/Write Vrms high voltage fault. It is limited to 125% of the
Condition: All 2 Min: 0.0 Voltage Input Rating. Fault operation is
Default: 576.0V Max: 750.0 further described in the Troubleshooting
Chapter.
Voltage Input Low Alarm The level compared to Vinrms that causes a
Read/Write Vrms low voltage alarm. It is limited to 100% of the
Condition: All 3 Min: 0.0 Voltage Input Rating. Fault operation is
Default: 384.0V Max: 600.0 further described in the Troubleshooting
Chapter.
Voltage Input Actual

5 Vrms Vinrms
Read only
7-1
Settings June 2008
Voltage Input Span

Bits Digital span adjustment of the voltage input
Read/Write 6 Min: 2000 signal. Calibration is described in the
Condition: All Max: 16000 Calibration Chapter.
Default: Factory
Frequency Rating
Hertz
Read/Write 12 Min: 50.0 The input line frequency rating.
Condition: Off Max: 60.0
Default: 60.0Hz
Frequency Actual
13 Hertz Calculated input line frequency.
Read only
Voltage Output Rating
Vrms
Read/Write The output rating of the voltage being
14 Min: 0.0
Condition: Off controlled by the 851.
Max: 2000.0
Default: 480.0V
Voltage Output PT The secondary voltage of an external voltage
Secondary Potential Transformer (PT). It is set equal to
Vrms
Read/Write the Voltage Output Rating if no PT is used.
15 Min: 0.0
Condition: Off It is very important that this setting be in the
Max: 600.0
Default: 480.0V same calibration range as the Voltage Input
Rating for proper operation.
Voltage Output Limit

Vrms The maximum voltage the voltage output PID
Read/Write 16 Min: 0.0 control will limit to. It is limited to 125% of the
Condition: All Max: 2500.0 Voltage Output Rating.
Default: 528.0V
Voltage Output Setpoint
Vrms The setpoint for the voltage output PID
Read/Write 17 Min: 0.0 control. It is limited to 100% of the Voltage
Condition: All Max: 2500.0 Output Limit.
Default: 480.0V
Voltage Output Proportional
Gain %
Read/Write 18 Min: 0.0 Voltage output control proportional gain.
Condition: All Max: 100.0
Default: 10.0%
Voltage Output Integral Gain
%
Read/Write 19 Min: 0.0 Voltage output control integral gain.
Default: 10.0%
Voltage Output Derivative
Gain %
Read/Write 20 Min: 0.0 Voltage output control derivative gain.
Default: 0.0%
7-2
June 2008 Settings
Voltage Output Actual

21 Vrms Voutrms
Read only
Voltage Output Zero
Read/Write Bits Digital zero adjustment of the voltage output
Condition: Off 22 Min: 0 signal. Calibration is described in the
Default: Factory Max: 100 Calibration Chapter.
Voltage Output Span

Bits Digital span adjustment of the voltage output
Default: Factory
Current Input Rating Irms
Read/Write Min: 0.0
31 The input rating of the current to the 851.
Condition: Off Max: 1500.0
Default: 200.0A (Ix10)
Current Input Limit Irms

The maximum current input the 851 will allow
Read/Write Min: 0.0
32 to run continuously. It is limited to 150% of
the Current Input Rating.
Current Input High Fault The level compared to the peak of Iinrms that
Irms
Read/Write causes an over current fault. It is limited to
Min: 0.0
Condition: All 33 350% of the Current Input Rating. Fault
Max: 5250.0
Default: 400.0A operation is described in the
(Ix10)
Troubleshooting Chapter.
Current Input High Fault

Retry Number The number of retries for the Current Input
Selection
High Fault before the fault is latched. Fault
Read/Write 34 Min: 0
operation is described in the
Condition: All Max: 5
Troubleshooting Chapter.
Default: 0
Current Input High Fault
Retry Time Seconds The time limit for fault retries before the fault
35
Read/Write Min: 10 will latch. Fault operation is described in the
Condition: All Max: 360 Troubleshooting Chapter.
Default: 10Sec
Current Input Overload Fault Irms The level compared to Iinrms that causes a
Read/Write Min: 0.0 timed current fault. It is limited to 250% of the
36
Condition: All Max: 3750.0 Current Input Rating. Fault operation is
Default: 250.0A (Ix10) described in the Troubleshooting Chapter.
Current Input Overload Time

Seconds The time limit on the current input overload
Read/Write 37 Min: 0 level before a fault occurs. Fault operation is
Condition: All Max: 360 described in the Troubleshooting Chapter.
Default: 10.0Sec
7-3
Current Input Actual Irms

41 Iinrms
Read only (Ix10)
Current Input Zero

Bits Digital zero adjustment of the current input
Default: Factory
Current Input Span
Bits Digital span adjustment of the current input
Condition: On Max: 16000 Calibration Chapter.
Default: Factory
Current Input Threshold
Load Failure Irms Ifailrms – The current used to determine a load
Min: 0.0 failure. It is limited from 2% to 10% of the
Read/Write 51
Max: 120.0 Current Input Rating. Fault operation is
Condition: All (Ix10) described in the Troubleshooting Chapter.
Default: 10.0A
Current Output Rating Irms
Read/Write Min: 0.0 The output rating of the current being
52
Condition: Off Max: 3000.0 controlled by the 851.
Current Output Limit Irms

The maximum current the current output PID
Read/Write Min: 0.0
53 control will limit to. It is limited to 150% of the
Current Output Rating.
Current Output Setpoint Irms

The setpoint for the current output PID
Read/Write Min: 0.0
54 control. It is limited to 100% of the Current
Output Limit.
Current Output Proportional

Gain %
Read/Write 55 Min: 0.0 Current output control proportional gain.
Default: 10.0%
Current Output Integral Gain
%
Read/Write 56 Min: 0.0 Current output control integral gain.
Default: 10.0%
Current Output Derivative
Gain %
Read/Write 57 Min: 0.0 Current output control derivative gain.
Default: 0.0%
Current Output Actual Irms
58 Ioutrms
Read only (Ix10)
7-4
June 2008 Settings
Current Output Zero

Bits Digital zero adjustment of the current output
Default: Factory
Current Output Span
Bits Digital span adjustment of the current output
Condition: On Max: 12000 Calibration Chapter.
Default: Factory
KVA Input Rating The KVA rating is the conversion factor that is
Read only used to convert the KVA Input from percent to
KVA. It is calculated using the following
KVA
64 equation.
(Ix10)
(Voltage Input Rating * Current Input
Rating)/1000
KVA Input KVA

65 Vinrms * Iinrms
Read only (Ix10)
Power Output Rating The output rating of the Power being

Read only controlled by the 851. It is calculated using
KW the following equation.
66
(Ix10)
(Voltage Output Rating *Current Output
Rating)/1000
Power Output Limit KW

The maximum power the power output PID
Read/Write Min: 0.0
67 control will limit to. It is limited to 125% of the
Power Output Rating.
Default: 96.0KW (Ix10)
Power Output Setpoint KW

The setpoint for the power output PID control.
Read/Write Min: 0.0
68 It is limited to 100% of the Power Output
Limit.
Default: 96.0KW (Ix10)
Power Output Proportional

Gain %
Read/Write 69 Min: 0.0 Power output control proportional gain.
Default: 10.0%
Power Output Integral Gain
%
Read/Write 70 Min: 0.0 Power output control integral gain.
Default: 10.0%
7-5
Power Output Derivative

Gain %
Read/Write 71 Min: 0.0 Power output control derivative gain.
Default: 0.0%
Power Output (Vin * Iin)rms , calculated by using the
KW
Read only 72 instantaneous product of the voltage and
(Ix10)
current samples.
Power Factor
73 Power Output/KVA Input.
Read only
Duty Cycle Output
74 % On time / Off time * 100.0 in percent
Read only
Duty Cycle Setpoint
%
Read/Write 75 Min: 0.0 The setpoint for open loop control.
Default: 100.0
Local Digital Control Display Defines what the Local Digital Control
Selection displays during operation. The Local Digital
Read/Write Control option is described in the Local
Condition: All Digital Control Option Chapter. The
Default: 1 selection list is:
Selection
1 – Voltage Output (V)
76 Min: 1
2 – Current Output (A)
Max: 8
3 – Power Output (KW)
4 – Control Setpoint (units)
5 – Voltage Output (%)
6 – Current Output (%)
7 – Power Output (%)
8 – Control Setpoint (%)
Local Digital Control The setpoint of the local digital control
Setpoint Vrms
module. It can be Vrms, Irms or KW
77 Irms
Read only depending on the setting of the regulation
KW
mode.
Local Analog Setpoint Vrms The setpoint of the local analog input. It can
Read only 78 Irms be Vrms, Irms or KW depending on the setting
KW of the regulation mode.
Analog Setpoint Zero

Bits Digital zero adjustment of the analog setpoint
Read/Write 79 Min: -100 input signal. Calibration is described in the
Default: Factory
7-6
June 2008 Settings
Analog Setpoint Span

Bits Digital span adjustment of the analog setpoint
Read/Write 80 Min: 2000 input signal. Calibration is described in the
Default: Factory
Analog Output Selection Defines the operation of the analog output.
Read/Write The selection list is:
Condition: All 1 – Power Setpoint
Default: 2 2 – Power Output
Selection 3 – Voltage Setpoint
85 Min: 1 4 – Voltage Output
Max: 10 5 – Voltage Input
6 – Current Setpoint
7 – Current Output
8 – Current Input
9 – Analog Setpoint
10 – Duty Cycle Output
Analog Output The programmed analog output as defined by
86 %
Read only Analog Output Selection in percent.
Analog Output Bias

Bits Digital zero adjustment of the analog output
Read/Write 87 Min: -100 signal. Calibration is described in the
Default: Factory
Analog Output Span
Bits Digital span adjustment of the analog output
Default: Factory
7-7
Control Word The control word is the digital inputs to the

Read/Write 851.
Condition: All Bit 0 – Maintained
Default: 1 – On
Bit 0 – 0 0 – Off
Off Bit 1 – Momentary
Bit 1 – 0 1 – Fault Reset
No Reset 0 – No Reset
Bit 2 – reserved Bit 3 – Momentary
Bit 3 – 0 1 – KW-hour Reset
No Reset 0 – No Reset
Bit 4 – reserved Regulation Mode
Bit 5 – reserved Bit 6 – 7 Maintained
Bit 6 – 0 93 Bits
0 – 0 Open Loop
Bit 7 – 1 1 – 0 Power Output
Voltage 0 – 1 Voltage Output
Bit 8 – 0 1 – 1 Current Output
No save Bit 8 – Momentary
Bit 9 – 0 1 – Save calibration to EEPROM
No restore 0 – No save
Bit 10 – 1 Bit 9 – Momentary
PING 1 – Restore calibration from EEPROM
Bit 11 – 15 – reserved 0 – No restore
Bit 10 – Maintained
1 – PING On
0 – Off
7-8
June 2008 Settings
Status Word The status word is the digital outputs from the
Read only 851.
Bit 0
1– On
0 – Off
Bit 1
1 – Fault
0 – No Fault
Bit 2
1 – Alarm
0 – No Alarm
Bit 3
1 – Remote control selected
0 – Local control selected
Bit 4
1 – Enable selected
0 – Inhibit selected
Bit 5
1 – Local Digital control
94 Bits
0 – Local Analog control
Regulation Limit
Bit 6 – 7 – 8
0 – 0 – 0 No Limit
1 – 0 – 0 Power Output Limit
0 – 1 – 0 Voltage Output Limit
0 – 0 – 1 Current Output Limit
0 – 1 – 1 Current Input Limit
1 – 1 – 1 Maximum Voltage Limit
Bit 9
1 – At Setpoint
0 – Not at Setpoint
Bits 10,11,14
Reserved
Bit 12,13
1,1 – Current Range is 0 – 10,000 Amps
0,0 – Current Range is 0 – 1,000 Amps
Bit 15
1 – Jumper JP3 In
0 – Jumper JP3 Out
Ramp Up Time
Seconds
Read/Write The amount of time for the setpoint to go from
95 Min: 0
Condition: All 0 to100%.
Max: 360
Default: 10 Sec
Ramp Down Time
Seconds
Read/Write The amount of time for the setpoint to go from
96 Min: 0
Condition: All 100 to 0%.
Max: 360
Default: 10 Sec
7-9
Configuration Word The configuration word configures the 851

Read/Write specific features of:
Condition: All Local Control Mode
Default: Bit 0 – Maintained
Bit 0 – 1 1 – Digital
Digital 0 – Analog
Bit 1 – 1 Thermostat Contacts
NC Bit 1 – Maintained
Bit 2 – 0 1 – NC
NO 0 – NO
Bit 9 – 1 External Fault Contacts
ALERT on low voltage Bit 2 – Maintained
Bit 12,13 – 0,0 97 Bits 1 – NC
Current range 0 – 1,000A 0 – NO
Bit 15 – 0 Low voltage alert/fault
No auto start Bit 9 – Maintained
1 – Low voltage causes an ALERT
0 – Low voltage causes a FAULT
Current Range
Bit 12,13 – Maintained
1,1 – Current Range 0 – 10,000 Amps
0,0 – Current Range 0 – 1,000 Amps
Auto Start on Powerup
Bit 15 – Maintained
1 – Auto start
0 – No auto start
Control Strategy Selection Defines the type of control strategy that is
Selection
Read/Write being run. The selection list is:
98 Min: 1
Condition: Off Max: 2 1 – Phase-Angle Control
Default: 1 2 – Zero-Crossover Control
Magnetizing Sequence
Calibration Cycles Number of cycles to ramp on in phase control
Read/Write 99 Min: 3 when running in Zero Crossover with
Condition: Off Max: 10 transformer coupled loads.
Default: 3
Repetitive Pulse Calibration
% Percent of first positive zero crossing pulse at
Read/Write 100 Min: 10 the beginning of each “on” cycle Zero-
Condition: All Max: 90 Crossover with transformer coupled loads.
Default: 60%
Load Type Selection Defines the type of load connected to the 851.
Selection
Read/Write The selection list is:
101 Min: 1
Condition: Off Max: 2 1 – Direct Coupled
Default: 1 2 – Transformer Coupled
Product Type
102 The product type is 851.
Read only
7-10
June 2008 Settings
Serial Number The numeric serial number of the 851. The

103
Read only setting is read as two consecutive words
104
Factory set because of its size.
Control Power Time On The accumulated time control power has been
105
Read only x.x Hours applied to the 851. The setting is read as two
106
Factory reset consecutive words because of its size.
Output Time On The accumulated time the 851 output has

107
Read only x.x Hours been on. The setting is read as two
108
Factory reset consecutive words because of its size.
KW-Hour The accumulated Power Output * Time in

Read only seconds. It can be reset remotely by writing a
109 x.x Hours
1 to bit 3 of the Control Word. The setting is
110 (Ix10)
read as two consecutive words because of its
size.
Software Version
112 The control software version read as xx.xxx.
Read only
Network Loss Defines the action the 851 takes when there is
Read/Write Selection a network loss. The selections are:
Condition: All 113 Min: 0
0 – Fault and stop
Default: 1 Max: 2
1 – Ignore and run
2 – Alarm and run.
Network Address For the DeviceNet™ and Profibus network
Read/Write types, defines the network interface card
Address
Condition: All address. For Ethernet, it defines the upper
114 Min: 0
Default: 63 two octets of the network address. Refer to
Max: 126
the network interface manual for a detailed
description of the network interface.
Network Baud Rate For the DeviceNet™ and Profibus network

Read/Write types, defines the network baud rate. For
Selection
Condition: All Ethernet, it defines the lower two octets of the
115 Min: 0
Default: 0 network address. Refer to the network
Max: 2
interface manual for a detailed description of
the network interface.
MODBUS Address
Read/Write Address
Defines the device address for MODBUS
Condition: All 116 Min: 1
messaging.
Default: 247 Max: 247
7-11
MODBUS Baud Rate Defines the serial baud rate. The selection list
Selection
Read/Write is:
Min: 4800
Condition: All 117
Max: 19200 4800
Default: 19200 (baud) 9600
19200
Network Type Defines the selected network interface. The
Read/Write selection list is:
Selection
Condition: All 118 Min: 0 0 – DeviceNet™
Default: 0 Max: 2 1 – Profibus
2 – Ethernet
Fault Code Fault condition code. Fault operation is

119
Read only described in the Troubleshooting Chapter.
Fault Index Index

Read only 120 Min: 1 Fault buffer index number.
Factory reset Max: 8
Fault Buffer #1 Saved fault condition code with a time stamp

121 of time run. Fault operation is described in
Read only 122 the Troubleshooting Chapter.
Factory reset 123 Word 121 – Fault condition code
Word 122/123 – Output time on stamp
7-12
June 2008 Settings

7-13
7-14
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
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 851 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 851 has a number of built in diagnostic features. These include LED indicators for quick visual
indicators on the following:
● the Main Control printed circuit board (PCB)
● the Local Digital Control option
● the network interface option
The four-digit display on the Local Digital Control option can be programmed to view key control signals
and display fault or alarm codes.
8-1
Troubleshooting June 2008
Control PCB LED Indicators
The control printed circuit board has six LED’s. Remove the middle wiring cover of the 851 to view these
particular LED’s. These LED’s and their functions are listed in the table below.
Table 8-1 Control PCB LED Indicators
LED Color Description
+5V Green +5V power is present
+15V Green +15V power is present
-15V Green -15V power is present
On Green 851 output is active
Heartbeat Flashing Digital Signal Processor is operating

Green
Fault Red 851 has detected a fault condition
Figure 8-1 Main Control PCB LED indicator location
8-2
June 2008 Troubleshooting
Local Digital Control Option LED Indicators
The Local Digital Control Option has six LED’s used for status. These LED’s are clearly viewed on the
bottom of the Local Digital Control Option. These LED’s and their functions are listed in the Table below.
Table 8-2 Local Digital Control LED Indicators
Status LED Color Description
Remote Green The Remote input is present.
Analog Green The Local mode is set to Analog.
Digital Green The Local mode is set to Digital.
Enable Green The Enable input is present.
On Green The 851 output is active.
Alert Amber Either a fault or alarm is present.
Figure 8-2 Local Digital Control
Fault and Alarm Codes
If there is a fault, the 851 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.
8-3
Alarm codes are warning conditions and do not stop the 851. 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 851. The following table lists the fault and alarm codes.
Table 8-3 Fault and Alarm Codes
Fault/Alarm Code Description
Current Input High 1 The fault occurs when the Current Input Actual peak
Fault exceeds the Current Input High Fault at any time during the
AC cycle for two consecutive cycles.
Note: The fault will be reset and automatically restart

based on the following conditions.
1. The 851 will turn off and automatically restart based

on the Current Input High Retry Number.
2. The 851 will turn off and not automatically restart if

the number of restarts occur within the Current Input
High Retry Time.
Current Input Timed 2 The fault occurs when all the following conditions are met.
Overload Fault
1. The Current Input Actual exceeds the Current
Input Overload Fault.
2. The accumulated time of condition #1 is greater than

the Current Input Overload Time.
Note: If the Current Input Actual goes below the Current

Input Overload Fault then the accumulated time resets back
to zero.
Over Temperature 3 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 1 of the
Configuration Word.
Voltage Input High 4 The fault occurs when the Voltage Input Actual exceeds the
Fault Voltage High Fault.
Voltage Input Low 5 The fault occurs when the Voltage Input Actual is lower than
Fault 12.5% of the Voltage Input Rating, and bit 9 of the
Configuration Word is NOT set.
8-4
SCR Shorted Fault 6 The fault occurs when the following conditions are met.
1. The Voltage Output Actual is greater than 75% of

the Voltage Output Rating for one second.
2. The 851 is off.
External Fault 10 The fault occurs when the external fault input changes to the
off state. The external fault input is defined as NO (Normally
Open) or NC (Normally Closed) depending on bit 2 of the
Configuration Word.
Configuration Fault 13 The fault occurs when the check byte of the onboard
EEPROM is not correct.
Note: This fault will cause all Settings to be reset to default

values on the next power up cycle.
Watchdog Fault 15 The fault occurs when the digital signal processor does not
update the watchdog timer correctly.
Network Loss Fault 16 The fault occurs if there is a network loss and the Network
Loss Selection is set to Fault and Stop.
Frequency Alarm 20 The alarm occurs when the Frequency Actual is outside of a
2.0 Hertz band as compared to the Frequency Rating
Voltage Input Low 21 The alarm occurs when the Voltage Input Actual is lower
Alarm than the Voltage Input Low Alarm.
Current Input Load 22 The alarm occurs when all of the following conditions are met.
Failure Alarm
1. The Current Input Actual is less than the Current
Threshold Load Failure.
2. The Voltage Output Actual is greater than 10% of

the Voltage Output Rating.
3. The setpoint has completed ramping up.
Voltage Output 23 The alarm occurs when the Voltage Output Actual is being
Limit Alarm limited to the Voltage Output Setpoint by the voltage output
control loop.
Current Output 24 The alarm occurs when the Current Output Actual is being
Limit Alarm limited to the Current Output Setpoint by the current output
control loop.
8-5
Power Output Limit 25 The alarm occurs when the Power Output Actual is being
Alarm limited to the Power Output Setpoint by the power output
control loop.
Current Input Limit 26 The alarm occurs when the Current Input Actual is being
Alarm limited to the Current Input Limit
Maximum Voltage 27 The alarm occurs when the Duty Cycle of the controller
Output Alarm reaches 100%.
Network Loss Alarm 28 The alarm occurs if there is a network loss and the Network
Loss Selection is set to Alarm and Run.
Fault Reset
Faults can be cleared or reset by three different methods. Alarms are automatically cleared.
● Toggle the Enable/Inhibit switch from Enable to Inhibit.
● Press the Reset button on the Local Digital Control module.
● Use the fault reset bit (bit 1) of the Control Word. The bit must be momentarily set to enable a
fault reset. The 851 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
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.
8-6
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
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 851 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 describes fault/alarm conditions with probable cause and corrective action for each
condition.
8-7
Table 8-4 Troubleshooting Guide
Condition Probable Cause Corrective Action
+5V LED off No Control Power Insure the 851 has separate control
power
+15V LED off
Power Supply connection Check Power Supply connections to
-15V LED off open main control PCB
Power Supply failed Replace Power Supply
Heartbeat LED off DSP on main control PCB Check that jumper JP3 is removed
failed before applying power
Replace main control PCB
Local Digital Local Digital Control Check Local Digital Control

Control Display off connection open or connection to main control PCB
or scrambled intermittent
851 will not turn on Enable not present Check that the Enable status LED is
in Local Analog on. The Output On status LED should
mode also be on.
Local mode not selected Check that the Remote status LED is
off.
Analog mode not selected Select Analog mode on Local Digital

Control. Check that the Analog status
LED on
Local Analog setpoint set to Verify voltage at Analog Setpoint input

zero
Local analog setpoint Verify Local analog setpoint

calibration incorrect calibration
8-8
in Local Digital on.
mode
Local mode not selected Check that the Remote status LED is
off.
Digital mode not selected Select Digital mode on Local Digital

Control. Check that the Digital status
LED is on
Output On not selected Press the On/Off/Reset pushbutton

and check that the Output On LED is
on.
Digital setpoint set at zero Press the increase pushbutton to

increase the setpoint
in Remote mode on.
Remote mode not selected Check that the Remote status LED is
on.
Network inoperable Check network cable and connections
Check 850 address and baud rate
Check the master device on the

network (scanlist)
On/Off bit not set to one Set the On/Off bit to one in the
Control Word and check that the
Output On LED is on
Setpoint set at zero Verify that the setpoints for Voltage,

Current, Power and Remote Duty
Cycle are not zero
851 cannot provide Calibration incorrect Check calibration

full power to the
load Power is being limited by one Verify setpoints for the three control
of the three control loops loops
8-9
851 is full on and cannot Duty Cycle is at 100.0%.

provide any more power
Review the load to verify that 100.0%
voltage will allow 100.0% power.
Verify input voltage level to make sure

it is not low
Output wiring intermittent or Check the output wiring

disconnected
Nuisance Input Improper fuse rating Refer to the Hardware Chapter for
Fuse blowing correct fuse rating
Fuse improperly tightened Tighten the fuses
F-01 - Current Input Calibration incorrect Check calibration

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

setting incorrect setting
Intermittent short in load Check load
F-02 – Current Input Calibration incorrect Check calibration

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

Current Input Overload Time Check Current Input Overload Time

Output transformer sized Verify size of output transformer

incorrectly
F-03 – Over Thermostat contact state Check Configuration Word setting

Temperature Fault incorrect in Configuration
Word setting
Thermostat wiring open or Check thermostat wiring

shorted
Cabinet is overheating Provide more cabinet ventilation or

cooling
8-10
Unit is Overheating Check fan is functioning properly
F-04 – Voltage Input Calibration incorrect Check calibration

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

Voltage Output PT Secondary Check Voltage Output PT

setting incorrect Secondary setting. Refer to the
Configuration Chapter for details on
correct setting
Incoming voltage out of Correct incoming voltage level

tolerance
F-05 – Voltage Input Calibration incorrect Check calibration

Low Fault
incorrect

correct setting
Blown input fuse Replace input fuse
F-06 – SCR Shorted Calibration incorrect Check calibration

Fault
Voltage Output Rating setting Check Voltage Output Rating setting
incorrect

correct setting
Shorted SCR Replace SCR
F-10 – External External Fault contact state Check Configuration Word setting
Fault incorrect in Configuration
Word setting
External Fault wiring open or Check External Fault wiring

shorted
8-11
F-13 – Failed EEPROM memory Replace main control PCB

Configuration Fault
F-15 Watchdog Failed DSP Replace main control PCB

Fault
F-16 - Network Loss Network failure Check network connection

Fault
Verify presence of network
Change Network Loss Option to

allow device operation
A-20 – Frequency Frequency Rating setting Check Frequency Rating setting

Alarm incorrect
Incoming frequency out of Correct incoming frequency

tolerance
A-21 – Voltage Input Calibration incorrect Check calibration

Low Alarm
incorrect
Voltage Input Low Alarm Check Voltage Input Low Alarm


setting incorrect Secondary
Incoming voltage out of Correct incoming voltage level

tolerance
A-22 – Current Input Calibration incorrect Check calibration

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

incorrect

Output load changed Verify output load
A-23 – Voltage Calibration incorrect Check calibration

Output Limit Alarm
incorrect
8-12

Voltage Output Setpoint Check Voltage Output Setpoint

Controlling with Voltage Change Voltage Output Setpoint

Output PID
A-24 – Current Calibration incorrect Check calibration

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

Controlling with Current Change Current Output Setpoint

Output PID
A-25 – Power Calibration incorrect Check calibration

Output Limit Alarm
incorrect

setting incorrect Secondary setting.
Current Output Rating setting Check Current Output Rating setting

incorrect
Power Output Setpoint setting Check Power Output Setpoint

incorrect setting
Controlling with Power Output Change Power Output Setpoint

PID
A-26 – Current Input Calibration incorrect Check calibration

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

incorrect
Controlling Current Input with Change Current Input Limit

Current Output PID
8-13
A-27 - Maximum Duty Cycle has reached Lower the control setpoint
Voltage Output 100%
Alarm
A-28 - Network Loss Network failure Check network connection

Alarm
Verify presence of network
Change Network Loss Option to

allow device operation
8-14
Appendix A
Mechanical Dimensions
Figure A-1 50A Model
A-1
Mechanical Dimensions June 2008
A-2
June 2008 Mechanical Dimensions
A-3
Appendix B
Electrical Drawings
B-1
Electrical Drawings June 2008
B-2
June 2008 Electrical Drawings
Figure B-1 Electrical Schematic
B-3
Figure B-2 - 50A Model
B-4
June 2008 Electrical Drawings
B-5
B-6
Glossary
Glossary of common terms and abbreviations used in SCR Power Controllers and their applications
Term or Acronym Description
ADR Automatic Device Replacement
ASCII American Standard Code for Information Interchange
Bias Calibration factor to offset signal at zero output of control signal
CAN Controller Area Network
CT Current Transformer
DSP Digital Signal Processor
DSPC Digital SCR Power Controller
EDS Electronic Data Sheet
Heatsink Device to carry heat from power devices
I2t Subcycle current characteristic of an SCR or fast clearing fuse
I/O Input/Output
IRMS Amps Root Mean Squared
KVA One thousand volt amperes
LED Light emitting diode
MOV Metal Oxide Varistor – brand name of GE transient voltage

suppressor
NC Normally closed contact
NO Normally open contact
NEC National Electric Code
NEMA National Electrical Manufacturers Association
ODVA Open DeviceNet™ Vendors Association
PCB Printed Circuit Board
PCMCIA Personal Computer Memory Card International Association
PCU Power Control Unit
i
Glossary June 2008
Term or Acronym Description
Phase Angle Control by chopping each half cycle
PID Proportional, Integral Derivative Controller
PLC Programmable Logic Controller
PT Potential Transformer
RFI Radio Frequency Interference
RMS Root Mean Squared
Rx Receive
SCR Silicon Controlled Rectifier
Semiconductor Solid State device for controlling electric power
Setpoint Reference for PID control
Silicon Material from which semiconductors are made
Span Calibration signal to adjust maximum input of control signal
Thyristor Name of semiconductor family including SCR’s, TRIAC, etc.
Tx Transmit
TXID Transaction ID for Explicit Message Requests and Responses
VAC Volts Alternating Current
VDC Volts Direct Current
VRMS Volts Root Mean Squared
Zero Calibration signal to adjust minimum input of control signal to zero
Zero-Cross Control by integrating numbers of complete cycles
ii

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June 2008

Safety Information in this Manual

Figure 1-1 851 DSPC Schematic Diagram................................................................... 1-1

Figure 1-1 851 DSPC Schematic Diagram

Figure 1-2 Phase-Angle Control Half Cycles

Phase-Angle Control Method

Figure 1-3 Phase-Angle Duty Cycle Output

Figure 1-4 Zero-Crossover Control

Zero-Crossover Control Method

Zero-Crossover Current Input Limit

Figure 1-5 Zero-Crossover Current Input Limit

Zero-Crossover Load Type

Figure 1-6 Zero-Crossover Control Magnetizing Sequence

Figure 1-7 Zero-Crossover Control Repetitive Pulse

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

 Locally, using an analog control signal.

• 1600 Volt SCR's

• 20KHZ pulse transformer coupled SCR gating circuit

• 50KHZ digital firing control

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

• Simultaneous regulation of voltage, current, and power

• User-configurable analog input

• User-configurable analog output

• Non-volatile storage of all digital settings

• Support of MODBUS RTU protocol

• Support of multiple baud rates on the serial port

The following optional features are available for the 851:

Table 1-1 Technical Specifications

Input Line Voltage 24 to 600 VAC RMS

Input Line Frequency 50/60 ± 2 HZ

Current Rating 50 to 600 A; higher ratings are available, consult factory

Short Circuit Current Rating 50 Hz 60 Hz

50/100A - 1,273ARMS 50/100A - 1,336ARMS

200A - 3,111ARMS 200A - 3,267ARMS

600A - 8,839ARMS 600A - 9,281ARMS

Fuse I2t Rating 50 Hz 60 Hz

50/100A - 16,200 A2sec 50/100A - 14,885 A2sec

200A - 96,800 A2sec 200A - 88,940 A2sec

600A - 781,250 A2sec 600A - 717,813 A2sec

Control Voltage 85 to 265 VAC

Analog Input 0 to 10 VDC or 0 to 20mA (250Ω)

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

Digital Input 0 to 5 VDC

Isolation to ground 2500 VAC

Ambient Temperature Range 0 to 50ºC

Floating Point Data and Current Range

The Part Number format for the 851 is described below.

Figure 2-1 Mounting Dimensions

The Phillips head cover screws are

Figure 2-2 Cover screw locations

Table 2-1 Wiring Information

Unit size Power Lugs Ground Lug Feedback Terminal

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

Remote Feedback Wiring

If remote feedback is used, the connections are

Note: The existing current and voltage feedback

The current feedback signal should be about 2.5

Figure 2-5 Remote Feedback Terminal

Control connections are made using the pluggable

The 851 requires 85-265VAC 50/60Hz @ 50VA

Figure 2-6 Control Connectors

Figure 2-7 Typical Control Connections

Table 2-2 Digital Interface Plug

Locally, using an analog control signal.