MANUAL FOR THE UNIVERSAL MANUAL CONTROLLER UMC - 31

MANUAL FOR THE UNIVERSAL MANUAL CONTROLLER UMC - 31 PPS PART NO. 133550 DRAWING NO. 133550-10 THIS MANUAL ASSIGNED TO THE S/N: THE INFORMATION CONTAINED IN THIS MANUAL IS PROPRIETARY TO PACIFIC POWER SOURCE, INC MAY NOT BE COPIED OR REPRINTED WITHOUT ITS EXPRESSED WRITTEN CONSENT. PACIFIC POWER SOURCE, INC. 17692 Fitch Irvine, CA 92614 REVISION A COPYRIGHT(C) PPS May 2012

Table of Contents PAGE 1.0 SCOPE... 1 1.1 USING THIS MANUAL... 1 1.2 GENERAL PRODUCT DESCRIPTION... 1 2.0 SPECIFICATIONS... 3 2.1 OUTPUT FREQUENCY... 3 2.1.1 FIXED FREQUENCY... 3 2.1.2 VARIABLE FREQUENCY... 3 2.2 OUTPUT VOLTAGE... 4 2.3 OUTPUT WAVEFORM... 4 2.4 OUTPUT FORMS... 4 2.5 OUTPUT METERING... 5 2.5.1 OUTPUT VOLTAGE... 5 2.5.2 OUTPUT CURRENT... 5 2.5.3 OUTPUT FREQUENCY... 5 2.6 ISOLATION... 6 2.7 INPUT POWER... 6 2.8 ENVIRONMENTAL... 6 3.0 INSTALLATION... 7 3.1 CONFIGURE THE NEW CONTROLLER... 7 3.1.1 SET OUTPUT FREQUENCY... 7 3.1.2 SET OUTPUT FORM... 7 3.1.3 SET for DIRECT or TRANSFORMER OUTPUT... 7 3.1.4 SET OUTPUT METERING FOR INTERNAL OR EXTERNAL SENSE... 8 3.2 REMOVE OR INSTALL CONTROLLER... 8 4.0 OPERATION... 11 4.1 CONTROLS AND INDICATORS... 11 4.1.1 VOLTS ADJUST... 11 4.1.2 FREQUENCY ADJUST... 11 4.1.3 OUTPUT COUPLING... 11 4.1.4 METER SELECT... 11 4.1.5 METER DISPLAY... 11 4.1.6 FREQUENCY INDICATOR... 11 4.2 AUXILIARY INPUTS... 13 4.3 DIGITAL OUTPUTS... 13 4.4 ANALOG OUTPUTS... 13 4.5 POWER SOURCE CONTROL... 13 5.0 CALIBRATION... 16 5.1 CALIBRATE OUTPUT FREQUENCY... 16 5.2 CALIBRATE FREQUENCY METER... 16 5.3 CALIBRATE VOLTMETER... 17 5.4 CALIBRATE AMMETER... 17 5.5 CALIBRATE CURRENT COMPENSATION... 18 i

List of Figures PAGE FIGURE 1 UMC-31 BLOCK DIAGRAM... 2 FIGURE 3.22 UMC-31 CONFIGURATION JUMPER LOCATIONS... 9 FIGURE 3.33 UMC-31 INSTALLATION... 10 FIGURE 4.1 UMC-31 FRONT PANEL CONTROLS... 12 FIGURE 4.32 J5 AUX I/O CONNECTOR ON SCU OR POWER SOURCE... 14 FIGURE 4.43 J3 CONT/OSC CONNECTOR ON SCU OR POWER SOURCE... 15 FIGURE 51 UMC-31 CALIBRATION ADJUSTMENT LOCATIONS... 19 ii

SECTION 1 SCOPE 1.0 SCOPE This manual provides the information required to use the Universal Manual Controller (UMC) effectively. This manual is an Operations Manual. Installation, operation and calibration are the principal subjects of this manual. 1.1 USING THIS MANUAL It is very important that the user reads section 4 prior to using this equipment. A thorough understanding of this section is required to operate this equipment properly. If questions arise while reading this manual, the user is encouraged to call the Pacific Power Source Inc. Pacific maintains a toll-free number which is 1-800-854-2433 (1-949-251-1800 outside the US), FAX 1-949-756-0756 Section 5 discusses calibration. This section needs to be read only when such activities are required to be performed. 1.2 GENERAL PRODUCT DESCRIPTION The UMC-31 Controller is a manually controlled, precision, three phase, sine-wave oscillator. It is capable of generating frequencies from 45-500 Hz, in single, two, or three phase mode. The user may select one of three fixed or the variable frequency range via internal jumpers. Fixed frequency settings are crystal-controlled to provide extremely stable operation. Full parameter metering is provided by the UMC-31 Controller. Output volts (line-to-line and line-to-neutral), output current, and output frequency are measured by the metering circuits of the UMC-31 Controller. The meter is a 3½ digit LED type. Typical accuracy of the meter circuits is 0.5%. Current compensation is also provided for use with transformer-coupled outputs. This feature allows the user to compensate for real losses due to distribution lines. Current compensation can be disabled at the user's discretion. The UMC-31 Controller is one of several designed for use with the AMX-Series AC Power Source. It is completely interchangeable with all other AMX-Series controllers. The assembly number for the UMC is 133500. Figure 1 is a block diagram of the UMC. 1

SECTION 1 SCOPE 1.0 SCOPE (cont.) FIGURE 1 UMC-31 BLOCK DIAGRAM 2

SECTION 2 SPECIFICATIONS 2.0 SPECIFICATIONS This section states the electrical specifications of the UMC-31 Controller. 2.1 OUTPUT FREQUENCY The UMC-31 Controller is configured with three fixed frequency settings and one variable frequency range. One of the above is selected via jumper placement on the controller circuit board ( see Figure 3.2 ). Accuracy and stability are stated below. 2.1.1 FIXED FREQUENCY Fixed frequencies of the UMC-31 Controller are crystal controlled. The standard fixed frequencies are: 1) 50.0 Hz 2) 60.0 Hz 3) 400.0 Hz Accuracy: 0.01% Stability: Less than 5 ppm/ C 2.1.2 VARIABLE FREQUENCY The UMC-31 Controller is configured with a continuously variable frequency range. The output is controlled by a front panel 10-turn potentiometer. Adjustment Range: 45 to 500 Hz. Accuracy: 0.5% Stability: Less than 200 ppm/ C 3

SECTION 2 SPECIFICATIONS 2.0 SPECIFICATIONS (cont.) 2.2 OUTPUT VOLTAGE Voltage control of the UMC-31 Controller is continuously variable via a front panel 10 turn potentiometer. This control adjusts all three phases simultaneously. Balance controls (±10% adjustment range) are provided for Phases B and C. Output Voltage Range: VR1: 0 to 135 VAC l-n Direct Power Source Output VR1.5: 0 to 204 VAC l-n 1:1.5 Transformer-coupled Output VR2.0: 0 to 273 VAC l-n 1:2.0 Transformer-coupled Output VR2.5: 0 to 341 VAC l-n 1:2.5 Transformer-coupled Output NOTE: VR1.5, VR2.0, and VR2.5 Output Ranges are available on transformer-coupled units only. 2.3 OUTPUT WAVEFORM The UMC-31 Controller produces sine-wave output. Distortion: Less than 0.5% THD (0.3%, typical) at the output of the controller. 2.4 OUTPUT FORMS The UMC-31 Controller is suitable for use as a single, two, or three phase controller. Output form is selected via jumper placement on the controller circuit board ( see Figure 3.2 ). Single Phase Output: Configured by using only φa output. Two Phase Output: Defined to be Phase B separated from Phase A by 180, and both vectors equal in magnitude. This mode is also available via jumper placement, and is also commonly referred to as "Split-Phase". Three Phase Output: Defined to be three independent vectors separated equally (φb lags φa by 120 ; φc lags φa by 240 ). Phase Separation Accuracy: ± 1 4

SECTION 2 SPECIFICATIONS 2.0 SPECIFICATIONS (cont.) 2.5 OUTPUT METERING The UMC-31 Controller is configured with a 3½ digit LED panel meter. A Meter Select Switch is used to select either line-to-line voltage, line-to neutral voltage, phase current, or output frequency. 2.5.1 OUTPUT VOLTAGE Three voltmeter inputs are accommodated from the Power Source, one per phase. Phase-to-phase voltages may also be measured. Voltage metering is average responding, rms indicating. Range selection is automatic. RANGE RESOLUTION 0 180 VAC rms 0.1 VAC rms 180 600 VAC rm 1 VAC rms Accuracy is ± 0.5% of full scale for each range. 2.5.2 OUTPUT CURRENT Four ammeter inputs are provided, one per phase and neutral. Range selection is automatic. RANGE RESOLUTION 0 180 A rms 0.1 A rms 180 700 A rms 1 A rms Accuracy is ± 0.5% of full scale for each range. 2.5.3 OUTPUT FREQUENCY A frequency meter is provided to measure the output frequency of the UMC-31 Controller Range 45-500 Hz. Range selection is automatic. RANGE RESOLUTION 0 180 Hz 0.1 Hz 180 550 Hz 1 Hz Accuracy is ± 0.5% of full scale for each range. NOTE: The frequency meter measures the output of the local oscillator of the UMC-31. As a result, the frequency of an externally induced signal is not measured by the frequency meter of the UMC-31. 5

SECTION 2 SPECIFICATIONS 2.0 SPECIFICATIONS (cont.) 2.6 ISOLATION The circuits of the UMC-31 are connected to equipment ground for the purpose of operator safety. Metal knobs and manual controls are electrically connected to chassis to prevent operator shock hazard. (Requires the CHS terminal of the attached power source to be connected to earth ground for complete operator safety.) 2.7 INPUT POWER If the UMC is installed in a Standalone Controller Chassis (SCU), it operates from 115 or 230VAC, 47 to 440Hz. Input Voltage conversion is made via a screw driver slide switch on the rear panel. A six foot line cord is provided. Fuses are installed for input protection. The UMC module will obtain power from the Power Source or stand alone controller chassis in which it is installed. 2.8 ENVIRONMENTAL Temperature Range: Humidity Range: 0 to +55 C, Operating -20 to +75 C, Storage 0 to 95% RH, non condensing. 6

SECTION 3 INSTALLATION 3.0 INSTALLATION This section describes the installation of the UMC-31 into a Pacific Power Source, Inc AMX-Series chassis assembly. The UMC-31 is designed to be installed into any AMX-Series Power Source. This controller must be configured and calibrated when installed because signal levels (primarily I out meter signals) are not the same for the various AMX Power Sources. 3.1 CONFIGURE THE NEW CONTROLLER Jumpers must be installed for desired operation. See Figure 3.2 for the location of the various configuration jumpers. 3.1.1 SET OUTPUT FREQUENCY Place a jumper on either the 50 Hz, 60 Hz, 400 Hz, or VAR header to select the desired frequency. 3.1.2 SET OUTPUT FORM For 1φ operation, place jumpers on the 1φ and 2φ headers. Remove jumpers from both 3φ headers and the "<" header. For 2φ operation, place jumpers on the 1φ, 2φ, and on the 3φ header near P3A. Remove jumpers from the "<" and 3φ header near U5. For 3φ operation, place jumpers on both 3φ headers. Remove jumpers from the 1φ, 2φ and "<" headers. 3.1.3 SET for DIRECT or TRANSFORMER OUTPUT To force direct-coupled output, remove jumpers from the XMR and SW headers. To force transformer-coupled output, place a jumper on the XMR header. Remove jumper from the SW header. To allow the front panel switch to select direct or transformer-coupled output, place a jumper on the SW header. Remove jumper from the XMR header. 7

SECTION 3 INSTALLATION 3.0 INSTALLATION (cont.) 3.1.4 SET OUTPUT METERING FOR INTERNAL OR EXTERNAL SENSE The output metering circuits of the UMC-31 can be set to measured output parameters at one of two points. The first is INTERNAL Sense which measures at the output terminals of the system. The second is EXTERNAL Sense where the user installs leads from some externally located sense point to the External Sense Terminal Block on the power source chassis. Note that when external sense is used, the output voltmeter will read zero volts when the output contactor of the power source is open. To configure for internal sense, remove jumper from the REM header. To force external sense, install a jumper on the REM header. 3.2 REMOVE OR INSTALL CONTROLLER Remove or install controller as follows: 1. Remove all input power. 2. Remove the top cover from the chassis. 3. To remove UMC-31 controller: Unplug ONLY one end of cables from the UMC-31 PCB end: J2 from P2A, J3 from P3A, J5 from P5A, and J6 from P6A. Keep the other cable ends attached to the Power Source or stand alone controller chassis. Remove the two nuts that mount the controller to the chassis front panel. Lift the controller up and slip it over the front panel studs. Remove the controller from the chassis. NOTE: If you want to replace UMC-31 controller with a UPC controller, refer to UPC operation manual for UPC controller installation after removing UMC-31 controller. To install UMC-31 controller: Insert the controller behind the front panel of the chassis and onto the two front panel studs. Insert two nuts onto the front panel studs and tighten. Plug one end of cables to the UMC-31 PCB: J2 to P2A, J3 to P3A, J5 to P5A, and J6 to P6A. Attach the other end to the Power Source or stand alone controller chassis. Calibrate the controller (see section 5). Install the top cover. NOTE: If you want to replace UPC controller with UMC-31 controller, refer to UPC Operation Manual for UPC controller removal before installing UMC-31 controller. 8

SECTION 3 INSTALLATION 3.0 INSTALLATION (cont.) FIGURE 3.21 UMC-31 CONFIGURATION JUMPER LOCATIONS 9

SECTION 3 INSTALLATION 3.0 INSTALLATION (cont.) FIGURE 3.32 UMC-31 INSTALLATION 10

SECTION 4 OPERATION 4.0 OPERATION This section provides the information required to operate the UMC-31 Controller. Refer to Section 4 of this manual for general power source operating instructions. 4.1 CONTROLS AND INDICATORS Refer to Figure 4.1 4.1.1 VOLTS ADJUST The VOLTS ADJUST knob controls the output voltage. The center control is the master for all three output phases. φb and φc TRIM are for phase B and phase C voltage balance trim adjustments only. These controls work all of the time. 4.1.2 FREQUENCY ADJUST The FREQUENCY ADJUST knob controls the output frequency when the UMC-31 is set for variable frequency mode only. This control is disabled when the UMC-31is configured for any of the fixed output frequency settings (see section 3.1.1). 4.1.3 OUTPUT COUPLING The OUTPUT COUPLING switch selects DIRECT or TRANSFORMER coupled output if enabled by internal jumpers (see section 3.1.3). 4.1.4 METER SELECT The METER SELECT switch selects a metering function. The user can select line-toline voltage, line-to-neutral voltage, phase or neutral current, or frequency as the output parameter to be metered. 4.1.5 METER DISPLAY The METER DISPLAY indicates volts, amps, or frequency as selected by the Meter Select switch. 4.1.6 FREQUENCY INDICATOR The FREQUENCY INDICATOR lamps show which output frequency mode has been configured. 11

SECTION 4 OPERATION 4.0 OPERATION (cont.) FIGURE 4.1 UMC-31 FRONT PANEL CONTROLS 12

SECTION 4 OPERATION 4.0 OPERATION (cont.) 4.2 AUXILIARY INPUTS Refer to Figure 4.3 for the pin-out of J5. Three AUX Inputs are provided on J5, one per phase. J5 is located on the back panel of the Power Source. Input impedance of the AUX inputs is 600 ohms. The low side of these signals is tied directly to power supply common (equipment ground). The inputs are DC coupled and are algebraically summed to the oscillator outputs of the UMC-31. It should be noted that the AUX Inputs can be used as external inputs simply by setting the UMC-31 to 0 VAC output. The AUX Inputs have a voltage gain of 25 with respect to direct-coupled, power source output (5.00 VAC AUX IN = 125 VAC OUT ). The gain of these inputs is scaled appropriately when transformer outputs are used. Three AM (Amplitude Modulation) inputs are also provided on J5, one per phase. As stated above, J5 is located on the rear panel of the AMX Power Source chassis. The input impedance of the AM Inputs is also 600 ohms. The low side of these signals is tied directly to power supply common. A varying DC voltage is used to modulate the output. 0 to +5 VDC will cause a 0 to 100% increase in output voltage. 0 to -5 VDC will cause a 0 to 100% decrease in output voltage. 4.3 DIGITAL OUTPUTS Refer to Figure 4.3 for the pin-out of J5. Digital outputs on J5 are 0 to 5 VDC, positive logic. J5 is located on the rear panel of the Power Source. These signals are provided for the purpose of synchronizing test equipment to the output of the power source. Logic outputs are provided for Sync Output of φa analog output, and the DRM pulse clock which is 100 times the output frequency. 4.4 ANALOG OUTPUTS Refer to Figure 4.4 for the pin-out of J3. The sinewave outputs of the stand alone controller chassis are on J3. 4.5 POWER SOURCE CONTROL The UMC sends the control signals to the Power Source on J3. 13

SECTION 4 OPERATION 4.0 OPERATION (cont.) FIGURE 4.32 J5 AUX I/O CONNECTOR ON SCU OR POWER SOURCE 14

SECTION 4 OPERATION 4.0 OPERATION (cont.) FIGURE 4.43 J3 CONT/OSC CONNECTOR ON SCU OR POWER SOURCE 15

SECTION 5 CALIBRATION 5.0 CALIBRATION This section provides the information required to calibrate the UMC-31. The controller must be calibrated in the sequence stated below. Improper calibration will result if the operations stated below are performed out of order. 5.1 CALIBRATE OUTPUT FREQUENCY Configure for 50 Hz, fixed frequency operation. See section 3.1. Attach a frequency counter to the output of the Power Source and verify that the output frequency is 50 Hz ± 0.005 Hz. Configure for 60 Hz, fixed frequency operation. Verify output frequency is 60 Hz ± 0.006 Hz. Configure for 400 Hz, fixed frequency operation. Verify output frequency is 400 Hz ± 0.04 Hz. Configure for variable frequency operation. Turn the Frequency Adjust control fully counterclockwise. Verify that the output frequency is less than 45 Hz. Turn the Frequency Adjust control fully clockwise. Verify that the output frequency is greater than 500 Hz. If any of the above tests fail, return the unit for repair. 5.2 CALIBRATE FREQUENCY METER Configure for 50 Hz, fixed frequency operation. See section 3.1. Rotate the Meter Select switch to the Frequency position. Adjust R130 (see Figure 5) until the meter indicates 50.0. Configure for 400 Hz, fixed frequency operation. Adjust R132 (see Figure 5) until the meter indicates 400. If any of the above tests fail, return the unit for repair. 16

SECTION 5 CALIBRATION 5.0 CALIBRATION (cont.) 5.3 CALIBRATE VOLTMETER NOTE: The Frequency Meter MUST be properly calibrated BEFORE the voltmeter calibration is performed. Any time the Frequency Meter is calibrated, the voltmeter must also be re-calibrated. Configure for 60 Hz, fixed frequency, 3φ, direct-coupled operation (see section 3.1). Rotate the Meter Select switch to the VOLTS A-N/1φ position. Connect a 4½ digit voltmeter, 0.25% accuracy or better, from the φa output to neutral of the Power Source. Adjust the volts adjust control so that the 4½ digit voltmeter indicates 120.00. Adjust R131 (see Figure 5) until the UMC-31 meter indicates 120.0. 5.4 CALIBRATE AMMETER NOTE: The Frequency Meter MUST be properly calibrated BEFORE the ammeter calibration is performed. Any time the Frequency Meter is calibrated, the ammeter must also be re-calibrated. In order to accommodate the wide range of current transformer (CT) ratios of the Pacific Power Source, Inc. product line, the CT ratio must be set in the UMC-31 to match the Power Source current ratio. This is done by four trim-pots within the controller, designated R136 through R139. These must be set, at the factory or in the field, to agree to the Power Source CT ratio. Rotate the Meter Select switch to the AMPS A position. Connect a 4½ digit current meter, 0.25% accuracy or better, in series with the φa output of the Power Source. Apply a full-rated resistive load to φa. Adjust R136 (see Figure 5) until the UMC-31 meter indicates the same current as the 4½ digit current meter. Rotate the Meter Select switch to the AMPS B position. Connect a 4½ digit current meter, 0.25% accuracy or better, in series with the φb output of the Power Source. Apply a full-rated resistive load to φb. Adjust R137 (see Figure 5) until the UMC-31 meter indicates the same current as the 4½ digit current meter. Rotate the Meter Select switch to the AMPS C position. Connect a 4½ digit current meter, 0.25% accuracy or better, in series with the φc output of the Power Source. Apply a full-rated resistive load to φc. Adjust R138 (see Figure 5) until the UMC-31 meter indicates the same current as the 4½ digit current meter. Configure the UMC-31 Controller for 1φ operation. Rotate the Meter Select switch to the AMPS 1φ/N position. Connect a 4½ digit current meter, 0.25% accuracy or better, in series with the 1φ output of the Power Source. Apply a full rated resistive load to the 1φ output. Adjust R139 (see Figure 5) until the UMC-31 meter indicates the same current as the 4½ digit current meter. 17

SECTION 5 CALIBRATION 5.0 CALIBRATION (cont.) 5.5 CALIBRATE CURRENT COMPENSATION Current compensation is used by the UMC-31 to compensate for real losses due to output transformers. Current compensation is active only when the system is configured for transformer-coupled output. This step in the procedure should be performed only when the system is supplied with output transformers. NOTE: The Output Ammeter MUST be properly calibrated BEFORE calibration of Current Compensation is performed. Any time the Ammeter is calibrated, Current Compensation must also be re-calibrated. Configure for 60 Hz, 3φ, transformer-coupled operation. With no load attached, set φa output to desired voltage. Apply full-rated load to φa. Adjust R140 (see Figure 5) until the full load output voltage is the same as the no load output voltage. With no load attached, set φb output to desired voltage. Apply full-rated load to φb. Adjust R141 (see Figure 5) until the full load output voltage is the same as the no load output voltage. With no load attached, set φc output to desired voltage. Apply full-rated load to φc. Adjust R142 (see Figure 5) until the full load output voltage is the same as the no load output voltage. 18

SECTION 5 CALIBRATION 5.0 CALIBRATION (cont.) FIGURE 51 UMC-31 CALIBRATION ADJUSTMENT LOCATIONS 19