1051 Series Product Manual - English

July 2013
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)

i
Table of Contents

Product Description ..................................................................................................... 1-1
Standard Features ............................................................................................... 1-2
Optional Features ................................................................................................ 1-3
Technical Specifications ...................................................................................... 1-4
Part Number ........................................................................................................ 1-6
Hardware........................................................................................................................ 2-1
Installation ........................................................................................................... 2-1
Enclosure ............................................................................................................. 2-1
Enclosure Temperature ....................................................................................... 2-1
Vibration .............................................................................................................. 2-2
Mounting .............................................................................................................. 2-3
Wiring .................................................................................................................. 2-3
Control and System Connections ........................................................................ 2-3
Digital Inputs ........................................................................................................ 2-8
Digital Outputs & Relay Output ............................................................................ 2-9
Important Digital Output Considerations ............................................................ 2-10
Analog I/O .......................................................................................................... 2-13
User Analog Inputs ............................................................................................ 2-14
User Analog Outputs ......................................................................................... 2-16
Temperature Measurement and Control ............................................................ 2-17
Voltage Attenuation ........................................................................................... 2-18
Current Transformers and Burden Resistors ..................................................... 2-18
Configuration and Monitoring .................................................................................... 3-1
Configuration Software ........................................................................................ 3-1
Configuration Application Overview ..................................................................... 3-2
Configuration Menu Bar ....................................................................................... 3-3
Off-line Configuration ........................................................................................... 3-7
The Setup Tab ................................................................................................... 3-8
The Operation Tab ........................................................................................... 3-11
The Fault/Alarm Tab ........................................................................................ 3-13
The Network Tab .............................................................................................. 3-13
Custom Tab ..................................................................................................... 3-15
Storing the Configuration ................................................................................... 3-18
On-line Operation .............................................................................................. 3-20
Set the Unit IP Address ..................................................................................... 3-27
Edit Ethernet Connection Parameters ............................................................... 3-32
Zero Crossover Control and Transformer-Coupled Loads ................................. 3-36

ii
Calibration ..................................................................................................................... 4-1
Load Calibration from File .................................................................................... 4-2
Save Calibration .................................................................................................. 4-3
Selective Calibration ............................................................................................ 4-4
Analog Input Calibration ...................................................................................... 4-8
Analog Output Calibration .................................................................................. 4-11
Local Digital Control .................................................................................................... 5-1
Status Bar ............................................................................................................ 5-1
Run Display ......................................................................................................... 5-3
Setpoint Display and Edit ..................................................................................... 5-4
Control Setup and Edit ......................................................................................... 5-6
Fault Display ........................................................................................................ 5-8
Alarm Display .................................................................................................... 5-10
Identity Display .................................................................................................. 5-11
Network Display ................................................................................................. 5-12
Flexible Display Capability ................................................................................. 5-13
Display Mismatch............................................................................................... 5-17
Network Communication Options ............................................................................. 6-1
Integrated Ethernet vs. Industrial Network Add-On.............................................. 6-1
Integrated Communication Protocol MODBUS TCP ......................................... 6-1
Industrial Network Communication .................................................................... 6-11
Settings .......................................................................................................................... 7-1
Voltage Output Feedback Range: ..................................................................... 7-38
Status Word bit OK to Run ............................................................................... 7-38
Startup Operation .............................................................................................. 7-38
Zero Crossover Automatic Power Synchronization............................................ 7-39
Scaling of Power Data ....................................................................................... 7-46
Timed Digital Input Selections ........................................................................... 7-46
Alarm Bits and the Alarm Filter Setting ............................................................ 7-46
Faults, Alarms, and Troubleshooting ........................................................................ 8-1
Fault and Alarm Codes ........................................................................................ 8-3
Fault Reset .......................................................................................................... 8-4
Fault History ........................................................................................................ 8-4
Alarm History ....................................................................................................... 8-4
Troubleshooting Guide ........................................................................................ 8-5
Fuse Replacement ............................................................................................. 8-15
Sample Web-Server Setup .......................................................................................... A-1
Mechanical Dimensions .............................................................................................. B-1
Electrical Characteristics ............................................................................................ C-1
Control Power VA Requirements ........................................................................ C-6

iii
Spang 1050 Series, 1051 Watt Losses ............................................................... C-7
Agency Approvals ............................................................................................... C-8

List of Figures

Figure 1-1 1051 Block Diagram, 15 - 400 Amps ..................................................... 1-1
Figure 1-2 1051 Block Diagram, 600 Amp .............................................................. 1-2
Figure 2-1 Typical Enclosed Package Access ........................................................ 2-4
Figure 2-2 Digital Output Connection .................................................................... 2-10
Figure 5-1 Local Digital Control............................................................................... 5-1
Figure 5-2 Run Display ........................................................................................... 5-3
Figure 5-3 Voltage Setpoint Display (Output On) .................................................... 5-4
Figure 5-4 Voltage Setpoint Display (Enter or Discard) .......................................... 5-5
Figure 5-5 Control Setup ......................................................................................... 5-6
Figure 5-6 Control Setup, Edit Mode ....................................................................... 5-7
Figure 5-7 Fault Display .......................................................................................... 5-8
Figure 5-8 Fault History .......................................................................................... 5-9
Figure 5-9 Alarm Display ...................................................................................... 5-10
Figure 5-10 Identity Display .................................................................................. 5-11
Figure 5-11 Network Information Display .............................................................. 5-12
Figure 5-13 Unit Selection Keys ........................................................................... 5-14
Figure 5-14 Select New Unit ................................................................................. 5-15
Figure 5-15 Unit IP Address and Description ........................................................ 5-16
Figure 7-1 Phase Angle Start Voltage Waveform ................................................. 7-39
Figure 7-3 Worst case, 100% overlap ................................................................... 7-39
Figure 7-4 50% Overlap ........................................................................................ 7-40
Figure 7-5 Improved Synchronization, 10% Overlap ............................................. 7-40
Figure 7-6 Synchronized, 0% Overlap .................................................................. 7-40
Figure 7-8 39 Zone Example ................................................................................ 7-41
Figure 7-7 12 Zone Example ................................................................................ 7-41
Figure 7-9 39 Zone Synchronization Performance................................................ 7-41
Figure 8-1 Control Board LEDs ............................................................................... 8-2
Figure C-1 1051 Electrical Schematic .................................................................... C-3
Figure C-2 1051, 600 Amp Schematic ................................................................... C-5

iv
List of Tables

Table 1-1 Technical Specifications ................................................................................ 1-4
Table 2-1 UL-Rated Maximum Ambient Temperature .................................................. 2-2
Table 2-2 UL Minimum Enclosure Size ......................................................................... 2-2
Table 2-3 1051 Connectors, Control Board 123011000 ............................................... 2-5
Table 2-4 1051 Connectors, Option Board 123012xxx ................................................. 2-6
Table 2-5 Lug Torque Specifications ............................................................................. 2-7
Table 2-6 Digital Inputs................................................................................................... 2-8
Table 2-7 Digital Outputs ................................................................................................ 2-9
Table 2-8 Digital Output De-Rating .............................................................................. 2-11
Table 2-9 Analog Input Connections ........................................................................... 2-13
Table 2-10 Analog Output Connections ...................................................................... 2-16
Table 6-1 MODBUS TCP Message Header ................................................................. 6-2
Table 6-2 Read Multiple Registers request (FC 3) ........................................................ 6-3
Table 6-3 Read Multiple Registers response ................................................................ 6-3
Table 6-4 Write Single Register request (FC 6) ............................................................ 6-4
Table 6-5 Write Single Register response ..................................................................... 6-4
Table 6-6 Write Multiple Registers request (FC 16) ...................................................... 6-5
Table 6-7 Write Multiple Registers response ................................................................ 6-5
Table 6-8 Read/Write Multiple Registers request (FC 23) ............................................ 6-6
Table 6-9 Read/Write Multiple Registers response....................................................... 6-7
Table 6-10 Read/Write Multiple Registers Example ..................................................... 6-8
Table 6-11 MODBUS Exception Response .................................................................. 6-9
Table 6-12 MODBUS Exception Codes ........................................................................ 6-9
Table 6-13 Little Endian Notation ............................................................................... 6-10
Table 6-14 Output Assembly - Poll Write Reference .................................................. 6-15
Table 6-15 Input Assembly - Poll Read Reference ..................................................... 6-15
Table 7-1 List of Settings ................................................................................................ 7-1
Table 8-1 Fault and Alarm Codes (1051 Single Phase) ............................................... 8-3
Table 8-2 Troubleshooting Guide .................................................................................. 8-6
Table C-1 Control Power VA Requirements ......................................................... C-6
Table C-2 1051 Watt Losses ................................................................................ C-7
Table C-3 Agency Approvals ................................................................................ C-8

1-1
Chapter 1
Product Description
The Spang Power Electronics 1051 Single Phase Controller is one of a series of products based on
Spangs 1050 control design. The 1050 product family is well-suited for a wide variety of AC power
applications. The 1050 family are multi-processor-based designs that drive SCRs that feed a variety of
industrial heating loads. The 1051 design features short circuit protection, local or remote (networked)
operation, a variety of user-definable inputs and outputs, and the precise regulation of power, voltage,
current, temperature, or phase angle (duty cycle). The Spang Power Electronics 1050 power controller
series represent the next generation of power control for AC applications that require dependability,
flexibility and unmatched performance.
The 1051 Single Phase Controller has the following innovative features:
Low cost for premium feature set and performance
Expandable I/O interface for sophisticated system applications, including thermocouple interface
Browser based configuration tool for unit configuration, control, and monitoring
Use of removable SD memory card for storage of configuration files
Standard Ethernet MODBUS TCP network communication for unit configuration, control, and
monitoring plus a variety of optional industrial network interfaces (DeviceNet, Profibus, Ethernet/IP)
Book shelf style package to minimize panel space consumption
Integrated I
2
t fuse within touch proof package
Optional color touch screen for local interface

Figure 1-1 1051 Block Diagram, 15 - 400 Amps
Product Description July 2013
1-2

Figure 1-2 1051 Block Diagram, 600 Amp
Standard Features
The Spang 1051 Power Controller product offers the following features:
Flexibility. Configurable operating modes, ratings, limits, external inputs, and setpoints. It also
offers multiple firing modes within the standard hardware package; phase angle and zero-crossover
(burst firing).
On-Board Diagnostics. Fault and alarms memory (ten fault buffers and ten alarm buffers) provides
data for analysis that may indicate a need for process modification, troubleshooting or preventative
maintenance.
Computerized Setup and Calibration. Web-based configuration application for setup, calibration,
monitoring, control and diagnostics
Mechanical Design. Touch-proof packaging prevents unintentional contact with hazardous voltage.
A book-shelf style mechanical design allows efficient use of panel space when integrated into multi-
unit system configurations.
Advanced Process and Fault Monitoring. Real-time monitor of voltage, current, power,
temperature (optional) and fault/alarm conditions. Real-time adjustment of the setpoint.
Communication methods include:
Local, using an analog control signal
Local, using the configuration software application
Local, with optional Local Digital Control feature
Remote, using MODBUS TCP protocol over Ethernet and the standard Universal Comm port
Operates on universal line voltages, from 20 to 600 VAC and 50/60 Hz.
July 2013 Product Description
1-3

DSP-based control
1600 Volt SCR's
20KHZ pulse transformer coupled SCR gating circuit
True RMS calculation of voltage, current, and power at 60KHZ sampling
Simultaneous regulation of voltage, current, and power
User-configurable analog inputs and outputs
User-configurable digital inputs and outputs
Non-volatile storage of settings and configuration
Web-hosted user configuration tool (stored on 1051 unit)
Compliance: CE, UL/ cUL (400A and under), RoHS
Optional Features
The following optional features are available for the 1051:
Expanded IO, including remote voltage, current and temperature (thermocouple) feedback as well as
additional digital and analog I/O.
Network Interface, allowing for remote control and monitoring of the 1051.
Optional network interfaces include DeviceNet, Profibus, ETHERNET/IP, PROFINET, and Ethernet
MODBUS TCP (a second Ethernet MODBUS TCP port provided on the network interface board).
Local Digital Control. Color touch-screen LCD display allows the user to control and monitor unit
set points, output, and status.

1-4
Technical Specifications
Table 1-1 Technical Specifications
Input voltage 20 to 600 VAC
Input line frequency 47 to 63 Hz.
Control power 115VAC or 230VAC, 50/60 Hz.
Output voltage rating 0 to 600 VAC

maximum
Output current ratings See ordering information
Ambient temperature 0 to 50 C ambient
Humidity Up to 95% non-condensing
Maximum Elevation 1,000 m. above sea level
Cooling Fan power above 50A PCU; either 115VAC or 230VAC, 50/60 Hz
Regulation 1% (voltage, current, or power)
Analog control reference
Standard: One (1) configurable:
current (4 20 mA; 249 ohm impedance),
voltage (0 10 V; 1 Meg-ohm impedance),
or potentiometer;
50V common-mode limit;
12 bit A/D achieves better than 1% accuracy
Optional: One (1) additional; same configurable functionality
Optional temperature
reference
One (1) thermocouple input; 24 bit A/D achieves 0.25% accuracy
Digital control reference
PC based configuration application, Remote Display, or network
communication
Input voltage and current
feedback (internal)
Contains voltage and current feedbacks for input voltage and current
Output voltage feedback
(internal)
Contains voltage feedback for output voltage
Relay contact
One (1) Normally Open (N.O.) and One (1) Normally Closed (N.C.),
Form C type selectable functionality
Rating: 0.5A @ 125VAC (general purpose); 2.0A max @ 0 - 30VDC
(resistive)
relay can only be used in a Class 2 transformer circuit or a low voltage
limited energy circuit.
July 2013 Product Description
1-5

Analog outputs
Standard: Two (2) configurable voltage (0-5 V) or current (4-20 mA).
Optional: Four (4) additional; same configurable functionality.
Analog interface isolation
Differential inputs for sink or source signals
Sourcing outputs, commons are tied common and ground referenced
Digital inputs
Standard: Enable / Inhibit, Remote / Local, Two (2) inputs configurable
as alarm, fault, timed alarm, timed fault, fault reset, or output on.
Optional: Two (2) additional; same configurable functionality
Digital outputs
Standard: One (1) Form-C with dry-type contacts configurable as
alarm, fault, no fault, OK to Run, or Run (firing output).
Optional: Three (3) open-collector outputs; same configurable
functionality
LED indicators
POWER steady Green indicates Power Supply is okay
HEARTBEAT 1&2 flashing Green indicates processors are running
ENABLE steady Green indicates Unit Enabled
RUN steady Green indicates Output On
ALARM steady Yellow indicates alarm
FAULT steady Red indicates fault
Configuration port
Ethernet port for PC based browser access, Display connection, or
Ethernet MODBUS TCP network comm
Over temperature monitoring One (1) internally mounted thermal sensor.
Short circuit protection
Integrally mounted I
2
t fuse
SCCR rating: 15 - 400A, 100kA
Transient voltage protection RC networks across the SCRs (no MOVs)
Protection
15-600 Amps: IP20 with appropriately sized (user installed) power
cable through power cable access holes.
1000 Amps and higher: IP00
Network connectivity
Ethernet MODBUS TCP via configuration port;
Optional network interface for DeviceNet, Profibus, Ethernet/IP,
PROFINET, or Ethernet MODBUS TCP (a second Ethernet
MODBUS TCP interface)
Certifications UL/cUL (400A and lower; 600A pending), CE, RoHS, WEEE

1-6
Part Number
The Part Number format for the 1051 Single Phase Controller is described below.
1 0 5 1 - n n n n - a a n - aaa - n - n n
1) 2) 3) 4) 5) 6) 7)

Product Identifier
Current Rating (Amps)
Communication Options
Auxiliary IO Option
Control Power

Note (1) Current Rating
0015 = 15 Amp
0025 = 25 amp
0050 = 50 Amp
0100 = 100 Amp
0200 = 200 Amp
0300 = 300 Amp
0400 = 400 Amp
0600 = 600 Amp * UL/cUL certification pending

Note (2) Network Descriptor:
0 = No network comm
D = DeviceNet
P = PROFIBUS
E = Ethernet MODBUS TCP
I = Ethernet/IP
N = PROFINET

Note (3) Network Redundancy
0 = Single network card
R = Redundant network card

Note (4) Local Digital Control
0 = No Display
1 = Local Display
2 = Remote Display

Note (5) Auxiliary I/O Option
0 = No auxiliary I/O
T = Auxiliary I/O board with thermocouple option
TLV = Auxiliary I/O board with thermocouple option and low voltage feedback

Note (6) Control Power
1 = 115V, single phase, 50/60 Hz.
2 = 230V, single phase, 50/60 Hz.

Note (7) Special Configuration (00 = Standard configuration)

2-1
Chapter 2
Hardware
WARNING

The 1051 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.

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.

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.

Installation
Prior to installation, the 1051 should be carefully checked for shipping and/or handling damage such as
loose or broken parts or wires.
Enclosure
The 1051 must be mounted in a protective enclosure to prevent the hazard of electrical shock and also to
avoid exposing the circuitry to damaging contaminants. If the 1051 will be located in an area of dust,
falling debris, splashing or falling water, adequate protection must be supplied by a special NEMA or IP-
rated enclosure; such enclosures are available as part of an integrated power system.
Enclosure Temperature
The 1051 is rated at 50C maximum ambient temperature inside of an enclosure. If the 1051 is mounted
in an enclosure other than one designed and built by Spang Power Electronics, care must be taken to
allow sufficient cooling/ventilation. Consult the factory for enclosure temperatures above 50C.

Hardware July 2013
2-2
Table 2-1 UL-Rated Maximum Ambient Temperature
UL-Rated Maximum Ambient Temperature (degrees Celcius) *
15 100 Amps 50C
200 400 Amp 40C

* The 600A unit is rated for 50C (non- UL).

Table 2-2 UL Minimum Enclosure Size
UL Minimum Enclosure Size *
Current Rating
(Amps)
Height (inches) Width (inches) Depth (inches)
50 20 16 12
100 24 20 12
200 30 24 12
300 30 24 16
400 30 24 16
600 30 24 16

* Based on 150% dimensionally or to meet the wire-bending space, whichever is larger.

Vibration
If the mounting site has a vibration concern, the 1051 should be mounted using industry standard shock
mounting techniques.

July 2013 Hardware
2-3
Mounting
The 1051 power controller is designed to be mounted in a vertical orientation. Allow four inches above
and below the 1051 for adequate cooling. Allow additional room for wiring as required by the individual
application and applicable standards such as the National Electric Code.
The enclosed-package 1051 is designed for side by side mounting to minimize consumed panel space
and may be mounted with zero clearance between adjacent units.
All enclosed-package 1050 Series power controllers require flush mounting against a flat panel surface.
The flush mount provides a necessary and directed path for airflow to dissipate the expected watts
generated by the power semiconductors.
For any other mounting considerations, contact Spang Power Electronics.

Wiring
Wire should be sized in accordance with the appropriate specific code guidelines. Ambient operating
temperature should be taken into account.
DANGER

The user is responsible for conformance 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.

Control and System Connections
The 1051 uses a combination of Phoenix-style pluggable connectors, Molex crimp connectors, and quick
connect terminals.
Caution

When using the internal power supply to provide power for analog references (i.e. pot
control or shorting power to reference), the analog reference DIP switches must be
positioned as voltage inputs (DIP switch in the Open position). If the DIP switches are
not properly configured, the regulator/supply may not be able to achieve 100% reference.
This condition may prove damaging to board-level components.

WARNING


Hardware July 2013
2-4

Figure 2-1 Typical Enclosed Package Access

Removable covers,
allowing access to
PCB connections.
Refer to the appropriate 1050 user drawings for
PCB connections and layout.
Power wire
connection (typical)
Control wireways
(typical Top and Bottom)
July 2013 Hardware
2-5
Table 2-3 1051 Connectors, Control Board 123011000
Usage Plug # Description Size AWG Wire Size*
IO Connectors Control board 123011000
Digital IO J15 6 pin vertical through-hole pluggable 3.81mm 28-16 AWG
Relay contacts J16 3 pin vertical through-hole pluggable 3.81mm 28-16 AWG
Analog IO J17 7 pin vertical through-hole pluggable 3.81mm 28-16 AWG
System Connectors - Control board 123011000
Neutral Voltage
Sense
J1
2 pin vertical through-
hole pluggable
earlier models 3.81mm 28-16 AWG
current production 5.08mm 24-12 AWG
Input Voltage
Sense
J2 Quick Connect Terminal 0.187
Output Voltage
Sense
J3 Quick Connect Terminal 0.187
Input Current
Sense
J4 4 pin vertical through-hole pluggable 3.81mm 28-16 AWG
Heatsink
Temperature
J5
3 pin vertical through-hole Molex friction lock
header
0.1 centers
DSP JTAG J6 14 pin (2x7) vertical through-hole header 0.1 centers
microSD J7 8 pin microSD card slot
surface
mount

internal JTAG J8 10 pin (2x5) vertical through-hole header
0.05
centers

Ethernet J9 8 pin inverted Ethernet jack
8P8C
modular

SCR1 gate drive J10
header
0.1 centers
SCR2 gate drive J11
header
0.1 centers
Network Option J12 16 pin (2x8) vertical through-hole header 0.1 centers
Digital option J13 20 pin (2x10) vertical through-hole header 0.1 centers
Analog option J14 20 pin (2x10) vertical through-hole header 0.1 centers
Control Power J18 2 pin vertical through-hole pluggable 5.08 mm 24-12 AWG
Hardware July 2013
2-6
Earth Ground J19 Quick Connect Terminal 0.187
Test points
(internal use)
J20
J21
16 pin (2x8) right-angle through-hole header 0.1 centers
Display Power J22 2 pin vertical through-hole pluggable 3.81mm 28-16 AWG
Fan Power
J23
J24
2 pin vertical through-hole pluggable 3.81mm 28-16 AWG
DSP Boot JP1 3 pin (1x3) vertical through-hole header 0.1 centers
*Standard Metric Equivalent Wire Size, from IEC 60228
28-16 AWG 0.5 mm
2
1.5 mm
2
22-30 AWG 0.5 mm
2

24-12 AWG 0.5 mm
2
4 mm
2
22-18 AWG 0.5 mm
2
0.75 mm
2

Table 2-4 1051 Connectors, Option Board 123012xxx
IO Connectors - Option board 123012xxx
Digital IO
(option)
J6
J8
3 pin vertical through-hole pluggable
3.81mm 28-16 AWG
Temperature
(option)
J4 2 pin vertical through-hole pluggable 3.81mm 28-16 AWG
Analog IO
(option)
J5
J7
3.81mm 28-16 AWG
System Connectors - Option board 123012xxx
Remote Vout
J1
J2
2 pin vertical through-hole pluggable 3.81mm 28-16 AWG
Remote Iout J3 4 pin right-angle through-hole pluggable 3.81mm 28-16 AWG
Digital option J9 20 pin (2x10) receptacle 0.1 centers
Analog option J10 20 pin (2x10) receptacle 0.1 centers
Earth Ground J11 Quick Connect Terminal 0.187
*Standard Metric Equivalent Wire Size, from IEC 60228
28-16 AWG 0.5 mm
2
1.5 mm
2
22-30 AWG 0.5 mm
2

24-12 AWG 0.5 mm
2
4 mm
2
22-18 AWG 0.5 mm
2
0.75 mm
2

July 2013 Hardware
2-7
Table 2-5 Lug Torque Specifications
Lug Torque by Frame Size
Current Rating
(Amps)
Wire Range Lug Range (SI) Torque Torque (SI) Set Screw
15, 25 1X 2-14 AWG 1X 35- 2.5mm
2
25 Lbf-in 2.8 N-m
.060 [1.5mm]
Slot
50 1X 2-14 AWG 1X 35- 2.5mm
2
35 Lbf-in 4.0 N-m
.060 [1.5mm]
Slot
100 1X 250-6 AWG 1X 120- 16mm
2
225 Lbf-in 25.4 N-m 5/16 Hex
200 1X 500-1/0 AWG 1X 240- 50mm
2
300 Lbf-in 33.9 N-m 3/8 Hex
300 2X 250-6 AWG 2X 120- 16mm
2
225 Lbf-in 25.4 N-m 5/16 Hex
400 2X 500-1/0 AWG 2X 240- 50mm
2
300 Lbf-in 33.9 N-m 3/8 Hex
600 3X 500-1/0 AWG 3X 240- 50mm
2
300 Lbf-in 33.9 N-m 3/8 Hex
Control Terminal Boards
Connector Size Wire Range Lug Range (SI) Torque Torque (SI) Set Screw
3.81 mm 28-16 AWG 0.14 1.5 mm
2
6 Lbf-in 0.7 N-m
.025 [0.63mm]
Slot
5.08 mm 24-12 AWG 0.20 2.0 mm
2
6 Lbf-in 0.7 N-m
.025 [0.63mm]
Slot

Hardware July 2013
2-8
Digital Inputs
The 1051 provides two standard + two optional = four total user-configurable digital inputs. The digital
inputs will indicate a true condition when tied to 1051 ground by direct connection or through a switch or
relay rated for 15VDC and 10mA. Selectable functions are:
Not used
Alarm when Closed
Alarm when Opened
Fault when Closed
Fault when Opened
Fault Reset
Output On
Timed Fault when Open
Timed Fault when Closed
Timed Alarm when Open
Timed Alarm when Closed
Local Control = Analog
Firing Mode = Zero Cross

Table 2-6 Digital Inputs
Terminal
Number
Terminal description Standard operation
J15 1 Enable Input Shorting 1 to digital common enables the unit.
Open inhibits operation.
J15 2 Remote/Local Input Shorting 2 to digital common puts the unit into
remote mode. Open is local mode.
J15 3 Digital Common
J15 4 Digital Input 0 User-configurable
J15 6 Digital Common
Option Board 123012xxx
J6 3 Digital Common

July 2013 Hardware
2-9
Digital Outputs & Relay Output
The 1051 provides one relay output (standard), and three (optional) open-collector digital outputs. All
digital outputs are user-configurable. The relay output may be configured in the same manner as the
three optional digital outputs, which are open-collector outputs designed for driving externally powered
relays. The user-configurable selections are:
Not used
Run
Alarm
Fault
Alarm or Fault
Filtered Alarm
OK to Run
No Fault
Local Control Analog
Local Control Digital
Firing Mode Phase Angle
Firing Mode Zero Cross

NOTE for control pcb 123011000 revisions P and earlier: The relay and digital outputs will
momentarily energize (switching state) during the initial power up or reset sequence. For control pcb
123011000 revisions Q and higher, the relay and digital outputs will remain in "shelf state" during initial
power up and reset. For all revisions, all subsequent transitions are handled as a function of the defined
user-configuration and real time status of the power controller.
Table 2-7 Digital Outputs
Terminal
Number
Terminal description Standard operation
J16 1 Normally Open User-configurable, closed when active
J16 2 Relay Common
J16 3 Normally Closed Open when active
J8 1 Digital Power Relay flyback power provided TO the 1051.
J8 2 Digital Out 1 User-configurable, pulled low when active
J8 4 Digital Ground
J8 6 Digital Ground
Hardware July 2013
2-10
A typical output connection is shown below.

Figure 2-2 Digital Output Connection

Important Digital Output Considerations
The digital output pin labeled as Digital Out n is to be fed as a common-source power connection,
intended for relay coil diode suppression. It is NOT providing power. Digital Ground pins tie to GROUND
within the control board circuitry.
WARNING: The digital outputs should NOT be connected to a 24Vdc power supply with the negative
grounded at a different ground potential than the power controller.
WARNING: The digital outputs of multiple power controllers should NOT be tied to a common 24Vdc
power supply if the power controllers are at differing ground potentials.
If a relay with a coil-suppression diode is used, correct polarity must be observed when wiring the relay
coil; otherwise, the relays power supply could be shorted to ground.
Failure to wire the digital outputs properly will result in unrecoverable damage to the printed circuit board.
NEVER connect digital outputs or digital inputs to AC line voltages!

July 2013 Hardware
2-11
Digital Output De-Rating Information
The external DC power supply should be less than 50VDC. The current output total MUST be limited to
80 mA, with no individual output drawing more than 40mA.
The 1051 digital outputs are organized into two groups; each group uses a common integrated circuit

The particular integrated circuit used is a SN75468 (7 open collector Darlington transistors in a 16-pin
SOIC surface mount package. The thermal de-rating graph from the SN75468 data sheet is shown
below.

The current output should be restricted to about 80
mA.

Table 2-8 Digital Output De-Rating
# of Outputs Used
Continuous current in each
switch
Total current for package
1 360 mA 360 mA
2 220 mA 440 mA
3 160 mA 480 mA

The de-rating is based on a maximum junction temperature of 150C and a package thermal impedance
of 73C/W.
Hardware July 2013
2-12

Approximate power dissipation with a current of
360 mA is about 1.25 x .36 = 450 mW which
yields a junction temperature of about 73 x .45 +
70 = 103C.

A simplified method of assigning maximum
loading would be to allow a maximum of 160 mA
x 3 = 480 mA or 220 mA x 2 = 440 mA per group,
with a maximum of 360 mA per output. This
would mean that if one of three outputs in a group
used 200 mA, there would be 480 200 = 180
mA available for the other two outputs in that
group. The remaining available current can be
split while not exceeding the 360 mA maximum
single output limit.
July 2013 Hardware
2-13
Analog I/O
The 1050 series analog inputs may be thought of as being in two categories, user I/O and system inputs.
The user I/O consists of the analog inputs (one standard and one optional), and the analog outputs (six
total; two are standard and four are optional).
The standard controller, therefore, has three system analog inputs, two voltage inputs and one current
input. These inputs are pre-wired at the factory and connected for input voltage, output voltage, and
current measurements. The Auxiliary I/O Option board adds one voltage and one current input; they are
normally used for voltage and current feedback from the secondary of a voltage matching transformer.
Note: If the option board is present, the output voltage feedback comes from the option board,
and the output voltage feedback on the base control board is not used.
One temperature input may be added to the Auxiliary I/O Option card (the standard Auxiliary I/O Option
card does not include the temperature input feature).
Table 2-9 Analog Input Connections
Terminal
Number
Terminal description
Standard operation
Control Board 123011000
J17 1 Analog Power (+10v)
J17 2 AIn1+ User-configurable
J17 3 AIn1- User-configurable
J17 4 Analog Common
J17 7 Analog Common
J5 1 Analog Power (+10v)
J5 2 AIn2+ User-configurable
J5 3 AIn2- User-configurable
J5 4 Analog Common
J7 3 Analog Common
J7 6 Analog Common

Hardware July 2013
2-14
User Analog Inputs
The analog inputs (references) are designed to accept potentiometer, voltage, or current inputs.
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. The inputs may also be calibrated by the user to non-
standard configurations such as 0 to 5 VDC or 4 to 20 mADC input to achieve 0 to 100% setpoint.
Note: For (optional) temperature input, the Process Temperature Set Point Limit is the rating
used for scaling the temperature input from 0 100%. The Process Temperature Set Point Limit
is equal to 100% analog input.

Ref # Voltage Current Differential Single-ended
1 SW1-1 O SW1-1 C SW1-2 O SW1-2 C
2 (OB)SW1-1 O (OB)SW1-1 C (OB)SW1-2 O (OB)SW1-2 C
O = Open C = Closed (OB) Option Board

Caution

When using the internal power supply to provide power for analog references (i.e. pot
control or shorting power to reference), the analog reference DIP switches must be
positioned as voltage inputs (DIP switch in the Open position). If the DIP switches are
not properly configured, the regulator/supply may not be able to achieve 100% reference.
This condition may prove damaging to board-level components.

July 2013 Hardware
2-15
Ain1 PWR (+10V)
Ain1 Ref (+)
Ain1 Ref ()
Acom (GND)
Aout1 (+)
Aout2 (+)
Acom (GND)
1
2
3
4
5
6
7
1051 Analog Interface
( J17 ) Control Board
Example: 4-20mAdc Reference Signal from Sourced (or Sinked) Current Controller
Customer Reference:
PLC or Temperature Controller

SW1-1 = Closed (ON) Current Source
SW1-2 = Open (OFF) Differential
1 2 3 4
ON (closed)

4-20mAdc Ref (+)
4-20mAdc Ref ()
1051 Analog Dip Switch Settings
( SW1 ) Control Board
Ain1 PWR (+10V)
Ain1 Ref (+)
Ain1 Ref ()
Acom (GND)
Aout1 (+)
Aout2 (+)
Acom (GND)
1
2
3
4
5
6
7
Example: 0-10Vdc (or 0-5Vdc) Reference Signal from a Voltage Source
Customer Reference:
PLC or Temperature Controller

SW1-1 = Open (OFF) Voltage Source
SW1-2 = Open (OFF) Differential

0-10Vdc Ref (+)
0-10Vdc Ref ()
1 2 3 4
ON (closed)
Ain1 PWR (+10V)
Ain1 Ref (+)
Ain1 Ref ()
Acom (GND)
Aout1 (+)
Aout2 (+)
Acom (GND)
1
2
3
4
5
6
7
Example: 10Turn, 10K, 2W Potentiometer Controlled Reference Signal
Customer Reference:
Locally or Remotely Mounted Potentiometer

SW1-1 = Open (OFF) Voltage Source
SW1-2 = Closed (ON) Single Ended

Power (+10Vdc)
Wiper (Reference)
Common (GND)
1 2 3 4
ON (closed)

Hardware July 2013
2-16
User Analog Outputs
The analog outputs are user-configurable. The Analog Output Selection defines which internal signal is
assigned to each analog output. Each analog output will generate 0 to 20mA for 0 to 100% of the
selected internal signal. An internal 249 Ohm resistor may be applied internally via dip switch selection to
generate a 0 to 5 VDC signal. Note: The analog outputs momentarily range from zero to full output
during the initial power up or reset sequence of the control board. The power controllers actual output is
Off at this time.

Table 2-10 Analog Output Connections
Terminal
Number
Terminal description
Standard operation
Control Board 123011000
J17 4 Analog Common
J17 5 Aout 1 User-configurable
J17 7 Analog Common
J5 4 Analog Common
J7 2 Aout4 User-configurable
J7 3 Analog Common
J7 6 Analog Common

July 2013 Hardware
2-17

ANALOG OUTPUTS
Out # Voltage Current
1 SW1-3 C SW1-3 O
2 SW1-4 C SW1-4 O
3 (OB)SW2-1 C (OB)SW2-1 O
O = Open C = Closed (OB) Option Board

Temperature Measurement and Control
The 1050 series units have an option board analog (thermocouple) temperature channel and one
standard digital temperature channel devoted to the SCR heatsink. The option board thermocouple
channel uses an AD7793 24-bit A/D mounted on the Interface board, which communicates with the DSP
via the SPI bus (note that this thermocouple provides two temperatures the cold-junction reading and
the remote thermocouple reading. The cold junction temperature is labeled on-board temperature).
There is no external interface to the on-board temperature sensor; it is monitored using the Spang
Configuration Tool Application. The digital temperature sensor is internally mounted to the heat sink.
The option board (thermocouple) temperature channel has a common mode rejection at 50/60 Hz of 100
dB. The hardware has 150V (continuous) voltage isolation and is capable of sustaining 1000 VDC for 60
seconds.
Thermocouple Process Temperature Control (TC) is an optional outer control loop that acts as a master
control around the standard control (regulation) mode. (TC) setup includes setting the Thermocouple
Type, Process Temperature PID slow loop response, Process Temperature Setpoint, fault temperature,
and alarm temperature. The Thermocouple Process Temperature Control (TC) has four (4) modes of
operation:
1. Not used [default] -- There is no thermocouple connected; no alarm, fault, or control is available.
2. Monitor -- A thermocouple is connected but is used only to monitor the thermocouple
temperature. Fault and/or alarm temperature level can be set.
3. Control -- A thermocouple is connected and Process Temperature Control is used as the outer
(master) control loop.
4. Limit -- A thermocouple is connected and is used as a process limiting variable. If the measured
temperature exceeds the Process Temperature Setpoint Limit, the controller output is reduced
until the Process Temperature reaches the Process Temperature Setpoint Limit.
Hardware July 2013
2-18
Setpoint ramping in degrees C per Hour is available with up-ramp and down-ramp controlled
separately. Available thermal alarms and faults are:
Low temperature alarm
High temperature alarm
Time delayed high temperature fault
High temperature fault

These alarms and faults typically would represent a layered safety net at increasing temperature values.
A feed-forward input to the thermal control loop allows for process and environmental control additions to
the thermal loop, such as anticipation control.
The Process Temperature Set Point Limit is the rating used for scaling the temperature input from 0
100%. The Process Temperature Set Point Limit is equal to 100% analog input.
Voltage Attenuation
The gain control circuitry of the 1051 sets the gain of the input and output voltage sense channels to
optimize the accuracy of the A to D conversion. The circuitry is dependent upon the voltage feedback
range selection. The voltage feedback ranges are: 0 to 240 volts or 0 to 600 volts. An optional 0 to 40
volts and 0 to 115 volts remote feedback is available for low-voltage applications. Each range determines
the gain of the signal path before the A to D converter.
Current Transformers and Burden Resistors
The current transformer (CT) burden resistors are specified and installed such that 100% current output,
defined by the Current Output Rating, equals 2.5Vrms. For example, if a CT with a rating of 1000 to 1 is
used on a unit rated at 350A, the burden resistor would be 2.5V/.35A or 7.14 ohms.

3-1
Chapter 3
Configuration and Monitoring
The 1051 Power Control units are shipped with a default configuration installed. Settings and calibration
can be adjusted to fit specific application criteria. Spangs Configuration Tool software is a browser-
based Adobe Flash application.
Configuration Software
The minimum system requirements are:
Web Browsing with Shockwave Flash version 10.3.185 or newer;
10BaseT or 100BaseT wired Ethernet connection, addressed to match the 1051 unit;
Cat 5 network cable

The 1051 Configuration Tool Application allows off-line editing and storage of configuration files. The
Configuration app also allows on-line, real-time changes to the 1051 settings through the Ethernet
connection. The capabilities of the Configuration Application include: offline file storage and retrieval,
offline/online configuration, offline/online network configuration, calibration, operation, and monitoring.
The Configuration Tool App is delivered with the 1051 Power Control unit on an SD card, and web-served
from the unit. The app may be copied to a PC and/or hosted from another web server (simple http web-
server is needed; see Appendix).

Users of the Firefox browser (version 19.02 or newer) can open the Configuration Tool Application
directly from the PC without a web-server. Other browsers may have the same capability.

Unit Configuration July 2013
3-2
Configuration Application Overview
Note: For optimal viewing when running the Configuration Tool, Spang recommends a screen
resolution (on the host computer) of 1024 x 768 pixels.
Note: The default out-of-the-box IP address of the Spang 1051 Power Control unit is
192.168.0.101. The address is recorded on the SD card. To edit the address, refer to the section
titled Edit Ethernet Connection Parameters in this chapter.
To run the Configuration Tool from the host computer start menu, select:
Start button -> Programs -> Internet Explorer -> http://<address of the 1051 unit>/ConfigTool.html
The Configuration Application will initially be off-line, that is, the Tool will not have established
communication with the 1051. When off-line, it is possible to edit settings and configuration in a local
environment, and save the information on the host computer.
The figures that follow feature the Spang 1051 single phase product.

July 2013 Unit Configuration
3-3
Configuration Menu Bar
The 1051 Configuration Application menu bar is shown below. The older version included a menu item
described as Factory Default; the text has been replaced with Default Files. The new version has
additional selections.

File Menu

File Option Description (Offline)
Open

General

Calibration data

Network Setup

All Three
Select and open a configuration file from the host system. Configuration files
are of the form <filename>.xml.
Read only the ratings and other setup information from the selected xml file
Read only the calibration values from the selected xml file
Read only the network setup information from the selected xml file
Read all information from the selected xml file
Save Save current setup, calibration, and network information to a xml configuration
file on the host system.
Print Open the standard dialog box that provides the selection of a printer and print
characteristics.

3-4
Default Files Menu
In the following actions, the word Save refers to all available information in the PCU; the word Load
refers to all configurable parameters in the PCU.

File Option Description
Load Factory
Default
Load the factory default settings from a configuration file on the SD card to the
PCU. For assistance, please contact Spang Power Electronics.
Save Factory
Default
Save new factory default settings to the SD card from the PCU. This function is
available to authorized Spang personnel only.
Load Customer
Default
Note: The CUSTOMER.BIN file must exist on the micro SD card.
Option 1 (Manual Load): Load the customer default settings from a configuration
file on the SD card to the PCU. This action is accomplished via Configuration
Software.
Option 2 (Auto Load): Install jumper between positions 2-3 on JP1 (control board
123011000) prior to applying control power to the PCU. With the jumper in place,
the customer defaults will be loaded to the PCU EVERY time control power is
cycled.
Save Customer
Default
Note: A new CUSTOMER.BIN file will be saved on the micro SD card.
Save new customer default settings to the SD card from the PCU (password
protected function).
The default password is CUSTOMER. For assistance, or to change the
password, please contact Spang Power Electronics.

3-5
Update Menu

Update Options Description
Calibration Open a new form allowing calibration of the unit (refer to the Calibration chapter)
Time Set the Date and/or Time of the 1050 unit based on the Date time of the computer
running the configuration application. Date and time are based on UTC.

Temperature Menu

Temperature Description
Run Form Open a floating form to display temperature information.

Connection Menu

Connection
Option
Description
Configure Enter the IP address of the target 1050 power control unit
Online Open a connection to the target 1050
Offline Close the connection with the target 1050
3-6
Help Menu

Help Options Description
Manual Open a web page with links to 1051 documents (including this manual) in pdf
format.
Web Site Use the host computers internet browser to connect to the Spang website.
About Display information about the Configuration Tool application.

Menu Buttons

Button Description (Online)
Start/Stop Toggle the output of the 1050 unit (online only)
Fault Reset Send a Fault Reset input (online only; momentary input)

3-7
Off-line Configuration
Off-line configuration allows the user to edit the 1050 setup without actually writing information to the
controller. All work is done on the host computer and can be saved in an xml file.
Configuration files are of the form <filename>.xml and are read from and saved to the host computer. A
default configuration file is included in the documentation shipped with each 1050 product. To load a
configuration file from the host computer to the Configuration Tool application,

Select the File->Open menu option
Browse the files in the file open dialog, and select the desired configuration (*.xml) file.

The setting values from the selected configuration file are loaded into the Configuration Tool application,
and can be viewed and/or modified.
Note that real-time information, such as operating characteristics, calibration, and fault/alarm information
is not valid when the Configuration Tool is offline. The information most useful for offline programming is
included in the Setup, Fault/Alarm, Network, and Custom tabs.

3-8
The Setup Tab
The Setup tab includes sections for ratings and limits, control, PIDs, digital IO, and analog IO. The
sections appear in the box on the left. Click on a section name to view its associated settings.
A bright blue-colored background on the form indicates a value that is read-only; ie, cannot be changed
by the user.

3-9

3-10

3-11
The Operation Tab
The Operation tab includes operating setpoints and general real-time characteristics like input and
output voltage, current and power, analog inputs and outputs, frequency, temperature and any existing
fault or alarm. Most of the information on the Operation tab is read-only and undefined in the offline state.

3-12

3-13
The Fault/Alarm Tab
The Fault/Alarm tab includes the settings defining voltage, current and temperature fault/alarm levels.

The Network Tab
The Network tab contains the information necessary to set up the optional network interface. The
Network tab includes address and network loss settings, the network map, read data, and write data. The
sections appear in the box on the left. Click on a section name to view its associated settings.

3-14

3-15
Custom Tab
The Custom tab opens a new, blank form. Using the drag-and-drop method, the user can build a one-
page summary of desired information.

Use drag-and-drop to add settings to the custom form.

3-16

Double-click the line to remove a setting from the custom form.

3-17

3-18

Storing the Configuration
To save the configuration (settings and data) to an xml file on the host computer,
Select the File->Save menu option

3-19
Browse for file location,
Specify <filename>.xml, and click Save

3-20
On-line Operation
DANGER

WARNING

product life. Wiring or application errors, incorrect or inadequate AC supply, or excessive
ambient temperature may result in malfunction of the system.

On-line operation involves message exchange between the configuration application and the 1050.
Settings are read from and written to the 1050 using ModbusTCP protocol. On-line communication
allows real-time editing, monitoring and calibration of the 1050.
To establish on-line communication between the Configuration Tool application and the 1050 unit,
Establish a physical connection between the host computer and the 1050 unit using cat5 (wired
Ethernet) cable.
From the taskbar, select Connection Configure
Enter the IP address of the target 1050.
From the taskbar, select Connection Online

The status leds on the taskbar are described in the following table. The Heartbeat LED should ALWAYS
flash at a 500msec rate IF the Configuration Tool application has established a connection with the 1050
product.
LED Color Description
Heartbeat Green, flashing flashing Green indicates healthy comm status
Enable Green, steady steady Green indicates the unit is (hardware) enabled
Run Green, steady steady Green indicates the unit output is energized
Remote Green, steady steady Green indicates the unit is under network control
Fault Red, steady steady Red indicates the presence of a fault
Alarm Amber, steady steady Amber indicates the presence of an alarm
3-21
If the Config Tool Heartbeat LED does not flash, make sure the IP address is properly set; if so,
disconnect and reconnect the cable, close and restart the Config Tool and go on-line.

WARNING

Improper configuration of the settings can result in component damage or reduction in
product life. Application errors or improper calibration may result in malfunction of the
system.

When the Configuration Tool is communicating online with the 1050, status, control and setting
information is continuously read from the 1050 and updated in the Configuration Tool.
Note: The green-colored background indicates the online status of communication.

3-22

When the Configuration Tool is communicating online with the 1050 unit, it is possible to make changes
to settings and control information, but ONLY when the unit is under LOCAL CONTROL.
To edit a setting:
Click the mouse in the spreadsheet cell to be changed. Only the value column may be edited.
Once selected, enter the desired value or click a choice from the drop down list.
Press [Tab] or [Enter], or
Press [Escape] to cancel the edit.

Load Settings from a File
Configuration files are of the form <filename>.xml and are read from and saved to the host computer. A
default configuration file is included in the documentation shipped with each 1050 product. To load a
configuration file from the host computer to the Configuration Tool application,
Select the FileOpen menu option
Browse the files in the file open dialog, and select the desired configuration (*.xml) file

3-23
The user has four options as described below. The selected information will be written directly to the
target 1050 unit.

File Option Online Description
Open

General

Calibration data

Network Setup

All Three
Select and open a configuration file from the host system. Configuration files
are of the form <filename>.xml.
Load the ratings, limits, fault/alarm settings and other setup information from the
selected xml file to the target 1050
Load only the calibration values from the selected xml file to the target 1050
Load only the network setup information from the selected xml file to the target
1050
Load all information from the selected xml file to the target 1050

Factors Affecting Write Capability
Write capability from the configuration application to the 1051 is affected by several factors:
Information cannot be written from the configuration application to the 1050 if the Remote/Local input is
in Remote. Remote mode allows the 1050 to be controlled by a master device over an industrial network
such as DeviceNet, PROFIBUS, or EthernetIP.
The Configuration Tool application is considered to be a source of Local Digital control to the 1050. If the
1050 is operating under Local Analog control, setpoints cannot be written from the Configuration Tool to
the 1050.
The 1050 settings related to real-time 1050 status, such as voltage out, power out, current out, etc, are
Read Only, and cannot be written under any circumstances.
For safety and security, some setup and calibration information can be changed only when the unit output
is OFF.

3-24
Default Files Menu

File Option Description
Load Factory
Default
Load the factory default settings from a configuration file on the SD card to the
PCU. For assistance, please contact Spang Power Electronics.
Save Factory
Default
Save new factory default settings to the SD card from the PCU. This function is
available to authorized Spang personnel only.
Load Customer
Default
Note: The CUSTOMER.BIN file must exist on the micro SD card.
Option 1 (Manual Load): Load the customer default settings from a configuration
file on the SD card to the PCU. This action is accomplished via Configuration
Software.
Option 2 (Auto Load): Install jumper between positions 2-3 on JP1 prior to
applying control power to the PCU. With the jumper in place, the customer
defaults will be loaded to the PCU EVERY time control power is cycled.
Save Customer
Default
Note: A new CUSTOMER.BIN file will be saved on the micro SD card.
Save new customer default settings to the SD card from the PCU (password
protected function).
The default password is CUSTOMER. For assistance, or to change the
password, please contact Spang Power Electronics.

Update Menu

Update Options Description
Calibration Open a new form allowing calibration of the unit (refer to the Calibration chapter)
Time Set the Date/Time of the 1050 unit to match the host computer (UTC).
3-25
Temperature Menu
To open the floating temperature display, select
Temperature Run Form

The temperature Run Form can be displayed anywhere on the form.

3-26
Connection Menu

Connection
Option
Description
Configure Enter the IP address of the target 1050 power control unit
Online Open a connection to the target 1050
Offline Close the connection with the target 1050

Menu Buttons

Button Description
Start/Stop Toggle the output of the 1050 unit (online only)
Fault Reset Send a Fault Reset input (online only; momentary input)

3-27
Set the Unit IP Address
Each Spang 1050 power control unit must have a unique IP address on the Ethernet network.
The IP Address, subnet mask, and gateway address together determine the power controllers unique
identifier on the Ethernet network segment. Indeterminate network behavior will result if each device
on the Ethernet network does not have a unique IP address. Spang provides an industry-standard
default address, subnet mask, and gateway in the TCPIPCFG.txt file.
The address is read by the unit from the TCPIPCFG.txt file on the micro SD memory card installed in the
SD card slot on the 1050 power controller.
DANGER

WARNING

FOLLOW ALL FEDERAL, LOCAL, & PLANT SAFETY RULES & REGULATIONS.

To change the IP address of the power controller, the TCPIPCFG.txt file on the SD memory card can be
edited using a computer, micro SD card reader and any standard text editor.

SD memory card slot
(shown with SD card).
The slot is labeled
J7 on 1051 pcb.
3-28
To edit the SD card contents:
1. Turn off all main power / control power and lock out all related supply voltages.

2. Verify 1050 control power is off and remove the micro SD card from the 1050 power controller
(push the card in to eject).

3. Using a micro SD card adapter, install (add as a drive) the micro SD card on the computer.

4. Open the TCPIPCFG.txt file.

3-29

5. As factory shipped, the text file should be displayed in a similar format to the image below.
NOTE: Subnet mask may also be 255.255.255.0.

3-30
6. To alter the IP address, mask, gateway, unit name, etc. alter numeric strings based on network
scheme and application requirements.

NOTE: When editing, use ONLY blank or space between the numeric entries and descriptions;
do NOT use the tab character.

7. SAVE the TCPIPCFG.txt file. Do NOT change the filename. (For backup, copy the file to
another drive on the computer. Once copied, the backup file can be renamed).

8. EXIT the text editor program.

3-31

9. Safely remove (eject) the SD Card Hardware from the personal computer.

10. Physically remove the SD card adapter from the computer, and remove the SD card from the
adapter.

11. Properly install the SD Card back into 1050 power controller (push until the card clicks into
place).

12. Safely restore control / main power and verify the new address.

3-32
Edit Ethernet Connection Parameters
Both the Spang PCU and the LDC hardware include an 8 pin inverted Ethernet jack. The receptacle
accepts standard Ethernet cable with 8P8C modular connectors. The default configuration of the Spang
PCU is 100BaseT, Full-Duplex communication.
The configuration is read by the unit from the TCPIPCFG.txt file on the micro SD memory card installed
in the SD card slot on the 1050 power controller.
DANGER

WARNING

FOLLOW ALL FEDERAL, LOCAL, & PLANT SAFETY RULES & REGULATIONS.

To change the network connection behavior of the power controller, the TCPIPCFG.txt file on the SD
memory card can be edited using a computer, micro SD card reader and any standard text editor.

To edit the SD card contents:
1. Turn off all main power / control power and lock out all related supply voltages.
SD memory card slot
(shown with SD card).
The slot is labeled
J7 on 1051 pcb.
3-33

2. Verify 1050 control power is off and remove the micro SD card from the 1050 power controller
(push the card in to eject).

3. Using a micro SD card adapter, install (add as a drive) the micro SD card on the computer.

4. Open the TCPIPCFG.txt file.

3-34

5. As factory shipped, the text file should be displayed in a similar format to the image below.
NOTE: Subnet mask may also be 255.255.255.0.

3-35
6. To change the Ethernet connection behavior from the default setup (100baseT, Full Duplex) to
Auto-negotiate, replace the phrase100baseT with Auto in the first line of the TCPIPCFG.txt file
(see image below).

NOTE: When editing, use ONLY blank or space between the numeric entries and descriptions;
do NOT use the tab character.

7. SAVE the TCPIPCFG.txt file. Do NOT change the filename. (For backup, copy the file to
another drive on the computer. Once copied, the backup file can be renamed).

8. EXIT the text editor program.

3-36

9. Safely remove (eject) the SD Card Hardware from the personal computer.

10. Physically remove the SD card adapter from the computer, and remove the SD card from the
adapter.

11. Properly install the SD Card back into 1050 power controller (push until the card clicks into
place).

12. Safely restore control / main power.

Zero Crossover Control and Transformer-Coupled Loads
Overview
If the 1051 directly controls a resistive load, standard zero cross firing is deployed.

For transformer-coupled loads, a special tuning technique is used to avoid high peak current due to
transformer core saturation which can occur if power is re-applied while residual core magnetization
exists. The tuning process establishes a controlled soft startup of the transformer, avoiding high inrush;
desired output operation, and a defined shutoff of the transformer.

The settings used for tuning are:

Initial Pulse, in percent, is the phase-on for the first cycle of each 100-AC-cycle firing period. This
phase back of the first cycle is to limit the current of the magnetized transformer core.

Magnetizing Ramp, in AC cycles, is the phase-on for the very first firing into a transformer used to limit
the initial current surge caused by residual magnetization of the transformer core.

3-37
Tuning
Tuning the Initial Pulse and Magnetizing Ramp parameters for a transformer is best accomplished by
viewing the current waveform on a storage oscilloscope connected to test point TP3 (Input Current) and
ground. This is nominally a voltage signal of approximately 3 volts RMS. Set the Oscilloscope for 100
milliseconds per division, 5 volts per division.

Initially set the 1051 unit to a regulation mode of Duty Cycle, the Firing Mode to Zero Cross and a duty
cycle setpoint of 20%. Provide a load on the transformer of at least 30 % of its rated KVA.
Set the Magnetizing Ramp to 10 AC cycles, and the Initial Pulse to 50%.

Duty Cycle control;
Duty Cycle setpoint 20%.
3-38

Set the oscilloscope to single trigger and turn the 1051 output on. If an overcurrent fault occurs, increase
the Magnetizing Ramp by 10 AC cycles and if possible, increase the Current High Fault Ratio to Rating.
Look for current overshoots in the initial ramped set of AC waveforms. Increase the Magnetizing Ramp to
remove any overshoot on the ramped waveform.

Set the oscilloscope to 10milliseconds, and with the 1051 output on, continuous-trigger the
oscilloscope. Look for current overshoots on the initial AC waveform of the set of 20, and adjust the Initial
Pulse parameter (increase or decrease as needed) to eliminate any overshoot seen.

If an oscilloscope is not available, contact Spang Power Electronics for assistance.

Zero Cross Firing Mode;
Initial Pulse 50%;
Magnetizing Ramp 10 cycles

4-1
Chapter 4
Calibration
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

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 1051 to perform certain calibration procedures. Voltages on
many components are at incoming line or output voltage potentials. To avoid electric
shock hazard or damage to equipment, do not touch any energized electrical component
and set up all metering devices for measurements in a powered down/locked out state.
Failure to observe these precautions could result in severe injury or loss of life.

WARNING

product life. Wiring or application errors, or improper calibration may result in malfunction
of the system.

The 1050 power control unit is calibrated before shipment. Any re-calibration of the unit should be
performed by authorized service personnel.
Note that all voltage calibrations should be performed in Duty Cycle regulation mode with as close
to 100% output as possible, all voltage measurements should be made with a calibrated True RMS
volt meter, and all calibrations should be performed while the unit is in a No Fault or Alarm state
(i.e. NOT hindered by any limit settings, usually indicated by an alarm).
Calibration July 2013
4-2
NOTE: Turn main incoming power OFF, and open the Enable input. Control power must remain
ON. If control power is linked to the input bus, it must be externally supplied for the calibration
sequence.

Load Calibration from File
Using the Configuration Tool, it is possible to load calibration information from an xml file. On the menu
bar, select
File Open Calibration Data
Select the xml file to read calibration values from. The values will be written directly to the 1050 unit.

July 2013 Calibration
4-3
Save Calibration
Calibration information can be saved from the File menu using the Configuration Tool. On the menu bar,
select
File Save
Specify a location and xml filename on the host computer.

4-4
Selective Calibration
Use the Configuration Tool to calibrate individual signals.
Offset
The Offset calibration exercise adjusts the raw A/D values.

Step Action Description
1 Check to verify that the unit Power is lit and the HB LEDs are
blinking.
2 Establish on-line communication between the host computer and
the 1051. The unit must be under LOCAL control.
3 Set the Local Control Mode to DIGITAL.
4 Set the Regulation Mode for Duty Cycle Control.
5 Turn main incoming power OFF. Check with a calibrated True
RMS volt meter that there is no main incoming voltage (Phase to
Phase and Phase to Ground).
6 On the Main form, select the Setup->Rating tab.
7 Check/set the Voltage and Current Ratings and select the Voltage
Feedback Ranges.
8 On the menu bar, select
Update Calibration. Click the [Main] tab as shown below.
9 With a calibrated True RMS meter, measure incoming voltage at
the unit input terminals or other easily accessible location to the
input voltage bus.
10 The measured voltage should be zero (0) Volts. If not, verify all
connections in a de-energized state per the system/product
schematics and repeat the previous steps.
11 Click the [Set Offsets for RMS readings] button in the table
(lower right).

4-5

* Remote Current is applicable only when option board 123012xxx is used.

4-6
Input Zero

blinking.
3 On the Main form, select the Operation->General tab. Set the
Regulation Mode for Duty Cycle Control, and the Local Control
Mode to DIGITAL.
Feedback Ranges.
Update Calibration. Select the [Main] tab as shown.
9 With a calibrated True RMS meter, measure incoming voltage at
the unit input terminals or other easily accessible location to the
input voltage bus.
With a calibrated True RMS meter, measure the incoming current
(See system/product schematic).
10 The measured voltage/current should be zero (0). If not, verify all
connections in a de-energized state per the system/product
schematics and repeat the previous steps.
11 Increase the value of the Voltage/Current input zero cell until noise
and measurement errors are sufficiently suppressed. (Note:
setting these values too high may result in inaccurate behavior at
lower operating levels)

4-7
Input Gain

blinking.
3 On the Main form, select the Operation->General tab. Set the
Regulation Mode for Duty Cycle Control, and the Local Control
Mode to DIGITAL.
4 Verify that the Enable Input is open (Inhibited), preventing the
SCRs from firing.
Feedback Ranges.
Update Calibration. Select the [Main] tab as shown.
9 Enter the numeric value for the measured True RMS voltage in the
corresponding Meter (right-side) column of the table.
10 Click the corresponding [Set to Meter] button in the table (below
the Meter column).

Note: If the Gain is at zero, the [Set to Meter] function will not work. Set the gain to a non-zero
value and repeat steps 9 through 10.

4-8
Analog Input Calibration
All analog calibration percentages are based on rated values, specifically the rating of the
selected reference (e.g. current or voltage). 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% (40/50*100) to represent maximum current output.
Set the analog reference DIP switches on the interface PCB in order to properly measure the values.

On the menu bar, select
Update Calibration. Select the [Analog In] tab.

4-9
Analog Input Zero

blinking.
SCRs from firing.
4 Verify that the output is OFF.
Update Calibration. Select the [Analog In] tab as shown.
6 Input the desired control reference from an external source to
achieve 0% output into the corresponding terminals on the control
or option board.
7 With a calibrated True RMS volt meter, measure and verify that
the analog input reference signal is equivalent to your desired
lower-end reference signal for 0% Output (i.e. 4mA, 0VDC, etc.).
(If not, in a de-energized state, verify all connections to the 1051
and associated circuitry per the system/product schematics. Once
completed, repeat the previous steps.)
8 Click the [Set Zero] button on the form to set the zero point of the
reference

4-10
Analog Input Gain

blinking.
SCRs from firing.
Update Calibration. Select the [Analog In] tab as shown.
6 Input the desired control reference from an external source to
achieve 100% output into the corresponding terminal jumpers on
the control or option board
the analog input reference signal is equivalent to your desired
higher-end reference signal for 100% Output (i.e. 20mA, 5Vdc,
etc.). (If not, in a de-energized state, verify all connections to the
1051 and associated circuitry per the system/product schematics.
Once completed, repeat the previous steps.)
8 Set the value you want for the higher end reference (usually
100%) in the box next to the Set Value button.
9 Click the [Set Value] button on the form to set the analog gain.

4-11
Analog Output Calibration
All analog calibration percentages are based on rated values, specifically the rating of the
selected reference (e.g. current or voltage). 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% (40/50*100) to represent maximum current output.
Set the Analog Output Selection to Calibration Setpoint, to allow a full range of signal settings without
having to actually power up the unit. Once calibrated, re-set the Analog Output Selection to the desired
operational setting.

4-12
Analog Output Offset and Span
Main form, Setup->Analog tab
On the menu bar, select
Update Calibration. Select the [Analog Out] tab.
blinking.
SCRs from firing.
5 On the Main form, select the Setup->Analog tab.
6 Set the Analog Output Selection to Calibration Setpoint.
Update Calibration. Select the [Analog Out] tab as shown.
9 Set the [Calibration Setpoint] to a Value of 0.00%.
the analog output reference signal is equivalent to your desired
lower-end reference signal for 0% Output (i.e. 4mA, 0Vdc, etc.).
11 If the analog output is not at the desired signal level, adjust the
offset slidebar until the correct output is reached/measured.
12 Set the [Calibration Setpoint] to a Value of 100.00%.
the analog output reference signal is equivalent to your desired
upper-end reference signal for 100% Output (i.e. 20mA, 5Vdc,
etc.).
14 If the analog output is not at the desired signal level, adjust the
span slidebar until the correct output is reached/measured.

5-1
Chapter 5
Local Digital Control
The Local Digital Control is a full color touchscreen LCD display/control interface. The local digital control
monitors real-time unit status and operating information.
Both the Spang PCU and the LDC hardware include an 8 pin inverted Ethernet jack. The receptacle
accepts standard Ethernet cable with 8P8C modular connectors. The LDC can be connected directly to
the Spang PCU, creating an isolated network (local, point-to-point); alternatively, the LDC can be
connected to a standard Ethernet switch and communicate with any of several Spang PCUs existing on
the same network segment. The Spang LDC is configured for 100BaseT, Full-Duplex communication.

Figure 5-1 Local Digital Control
Status Bar
The upper portion of the LDC is dedicated to unit status. There 2 lines of text associated with unit status:
Unit description, Output Status, Enable/Inhibit, Remote/Local Status, and Analog/Digital Control mode.
Status Background
The background color of the status bar indicates whether the unit is Off or disconnected (Gray), On
(Green), Alarming (Amber), or Faulted (Red).
Local Display July 2013
5-2
Unit Description
The left-most field of status line 1 is a text field identifying the 1050 unit. The text is retrieved from the
.ini file on the micro SD card when the display is powered up. The description can be edited using a
micro SD card reader and any standard text editor. The Unit Description is limited to 16 characters.
Unit Output
The right of status line 1 indicates whether the unit output is ON or OFF. If the unit output is On and
there is no alarm (or fault), the status background is solid Green. If the unit output is Off and there is no
alarm (or fault), the status background is Gray.
Enable
The left-most field of status line 2 is a text field indicating the state of the Enable/Inhibit input. If the unit
is enabled, the word Enabled is visible in the field. If the unit is inhibited, the word Disabled is visible.
Network Control
If the unit is operating under Remote (network) control, the word Remote is visible in the center position
of status line 2. If the unit is operating under local control, the word Local is shown.
Fault/Alarm
The right-most field of status line 2 indicates fault or alarm status. A fault condition, if present, is noted by
the word FAULT is visible in the field. The status background will flash Red at a 1 second interval. If
no fault condition exists but an alarm is present, the word ALARM is visible. The status background will
flash Amber at a 1 second interval.
If communication between the display and the 1050 unit is lost (cable disconnect or flash programming,
for instance), or non-existent (the selected unit is not present on the network), the status bar will show
question marks on a Gray background.

July 2013 Local Display
5-3
Run Display
The default display mode is the Run display mode. The Run display mode indicates unit status,
setpoints, and output values for Voltage, Current, and Power.

Figure 5-2 Run Display

The ON/OFF key toggles unit output (local control only). The key is dark gray-colored when the unit is off
and bright green when the unit is on.
The Reset key [RES] sends a Fault Reset (momentary contact) to the unit.
The Previous [<] and Next [>] keys are used to select the display mode.
The icon on the left, below the status bar, indicates unit fault/alarm status: a fault is indicated by a red X
inside a circle; an alarm is indicated by a triangle with an exclamation mark as shown in the figure. The
output of the controlling loop is displayed on a blue background, with a key symbol to the right of it (in
this example the unit is in voltage control). Note that under temperature control, the secondary control
output will appear on a blue background without the key symbol.
Press Next [>] to move to the Setpoint display mode.
5-4
Setpoint Display and Edit
The Setpoint display mode allows monitoring and editing of the setpoints of the 1050: Voltage, Current,
Power, Duty Cycle and Temperature.

Figure 5-3 Voltage Setpoint Display (Output On)

In the figure above, the blue background and key symbol indicate that the unit is in Voltage Control.
The upper Previous [<] and Next [>] keys move from setpoint to setpoint.
5-5

Figure 5-4 Voltage Setpoint Display (Enter or Discard)

Use the Increment [+] and Decrement [-] keys to modify the setpoint value.
Press the Enter key to write the new setpoint to the unit.
Press the Cancel key to cancel the edit.
Use the Previous and Next keys at the top of the display to cancel the edit and move to the next
setpoint.
Use the lower Previous and Next keys to change the display mode. Press the lower Next key to enter
the Control Setup display mode.

5-6
Control Setup and Edit
The Control Setup display mode allows monitoring and editing of certain control settings of the 1050:
Local Control Mode, Regulation Mode, Firing Mode and Analog Reference #1 Selection.

Figure 5-5 Control Setup

The upper Previous [<] and Next [>] keys move from setting to setting within the Control Setup menu.
The middle Previous [<] and Next [>] keys move among the selections for the control setting.

5-7

Figure 5-6 Control Setup, Edit Mode

The middle Previous [<] and Next [>] keys move among the selections for the control setting.
Press the Enter key to write the new selection to the unit.
Press the Cancel key to cancel the edit.
Use the Previous and Next keys at the top of the display to (cancel the edit and) move to the next
setting.
Use the lower Previous and Next keys to (cancel the edit and) change the display mode. Press the
lower Next key to enter the Fault display mode.
5-8
Fault Display

Figure 5-7 Fault Display

The Fault display mode is monitor-only. The initial information shown in the Fault display is the active
fault condition (if any).
If a fault is indicated, the user can press the [RES] key to attempt a Fault Reset. If the condition causing
the fault persists, the unit will remain in a faulted state.

5-9

Figure 5-8 Fault History

Press the upper Decrement [<] and Increment [>] keys to scroll through the Fault History, a circular
buffer which stores the last 10 faults to have occurred.
Press the lower Previous [<] key to enter the Control Setup display.
Press the lower Next [>] key to enter the Alarm display.

5-10
Alarm Display

Figure 5-9 Alarm Display

The Alarm display mode is monitor-only. The initial information shown in the Alarm display is the active
alarm condition (if any).
An alarm will clear automatically when/if the condition causing the alarm is resolved.
Use the upper Previous [<] and Next [>] keys to scroll through the Alarm History, a circular buffer which
stores the last 10 alarms to have occurred.
Press the lower Previous [<] key to enter (return to) the Fault display.
Press the lower Next [>] key to enter the Identity display.

5-11
Identity Display

Figure 5-10 Identity Display

The Identity display, also called the splash page, provides revision information about the 1051 display.
The third line of the information text will indicate Init OK if all parameters and touch calibration data has
been read from the Micro SD memory card installed in the top of the display.
Should there be any problem with key data, the third line will indicate the nature of the issue.
Entering this page starts a 10-second display timer. After ten seconds elapse with no keypress, the
display will move to the Run display mode.

Press the Previous [<] key to enter the Alarm display.
Press the Next [>] key to enter the Network display.

5-12
Network Display

Figure 5-11 Network Information Display

The top box shows the MAC ID of the display, the second box shows the actual IP address of the display
and the third box shows the IP address of the 1051 unit this display is monitoring. The IP addresses and
associated strings are stored on the micro SD card on the display pcb in the text file TCPIPCFG.txt.
It is possible to edit the descriptive strings for the control unit and the display. To edit the selections,
remove the micro SD card from the display pcb. Use a micro SD card reader to attach the SD card to a
read/write device. The file TCPIPCFG.txt can be edited using any text editor. NOTE: Care must be
taken to preserve the order of entries in the TCPIPCFG.txt file.
When editing the address/description selections, use only blank or space characters between the IP
address and description; do NOT use the tab character.

5-13
Flexible Display Capability
It is possible to use one 1051 LDC to monitor any 1051 power control unit on the Ethernet network. Each
Spang 1051 must have a unique address on the Ethernet network. Up to 100 IP address/description
combinations can be stored on the displays micro SD card, one combination per line, following the LDC
address/description, the network mask, and the gateway address. Use only blank or space characters
between the address and description; do NOT use the tab character. The description should be no more
than 16 characters in addition to the IP Address.

Figure 5-12 Multiple Unit Display

To select a different Spang 1051 unit to monitor from the 1051 display, lightly press the center of the
Status bar on the Run display.

5-14

Figure 5-13 Unit Selection Keys
Use the Selection keys to scroll through Address/Description selections stored in the file TCPIPCFG.txt
on the displays micro SD card.
Sample TCPIPCFG.txt
Sample strings in the TCPIPCFG.txt file:

Text File Line IP Address and Description Notes
Line 1 10.4.60.209 1051 Display Display IP Address
Line 2 255.255.255.0 Mask IP mask
Line 3 10.4.0.1 Gateway Gateway address (if used)
Line 4 10.4.60.210 1051 Zone 1 first selection
Line 5 10.4.60.202 1051 Zone 2 second selection
10.4.60.203 1051 Zone 3
Text File Line 103 (maximum) as many as 100 selections
5-15

Figure 5-14 Select New Unit

Press the Enter key to select a different 1051 unit from the list of choices on the SD card. The display
will write the new selection to the .ini file, then immediately reset and attempt to connect with the new
1050 unit.
5-16

Figure 5-15 Unit IP Address and Description

Press the Escape key, the Status bar, or the lower Previous [<] or Next [>] key to cancel the edit.
If there are no keys pressed within 30 seconds, the Control Selection display will time out, cancel the
edit, and return to the Run display.
If the selected 1050 unit is not found on the Ethernet network, the display will reset and attempt to
establish communication every 10 seconds until the connection is made or the selection is changed.

During powerup, the display reads its 1050 unit connection information from a simple text file called
ControlIP.ini. The file is stored on the displays micro SD card along with the TCPIPCFG.txt file. The
1050 unit IP address stored in the .ini file becomes the default target for the display. On power down or
before a reset, the display writes the chosen unit IP Address and description to its .ini file.

Display ControlIP.ini file
Example of the ControlIP.ini file before selecting another 1050 unit:
10.4.60. 200 Control IP Address
Example of the ControlIP.ini file after the above change:
10.4.60.203 1051 Zone 2
Note: If the micro SD card is not installed in the display, or if the file ControlIP.ini does not exist on the
SD card, the display will not connect to any 1050 unit on powerup. However, as long as the
TCPIPCFG.txt contains at least one 1050 IP Address/ description combination, the display can be
configured to connect to the unit.

5-17
Display Mismatch
Because certain product-specific information is embedded in the 1051 LDC display, it is NOT currently
cross-product compatible among the 1050 series.
If the targeted 1050 control unit is not the same product type or variant as the 1051 LDC display, the
message shown below will appear in the Status bar.

Select a different Spang unit to monitor from the units included in the TCPIPCFG.txt file by pressing
lightly the center of the Status bar, and proceeding as outlined previously.
5-18

6-1
Chapter 6
Network Communication Options
The Spang 1050 power control products are capable of several forms of messaging with other intelligent
devices. The messaging ability of the 1050 allows supervision and control of the 1050 by a master
device. Communication between the 1050 and other intelligent devices is available in two forms: local
monitoring and control using the integrated Ethernet connection; or remote monitoring and control across
an industrial network (DeviceNet, PROFIBUS, Ethernet/IP, PROFINET, or Ethernet MODBUS/TCP),
which requires the appropriate Spang network interface.

Integrated Ethernet vs. Industrial Network Add-On
The primary usage for the integrated Ethernet port is configuration of the 1050 unit and support for
optional display units. Although it may be utilized as a network control connection, key functionality
differences from an add-on network card must be noted: 1) There is no network time-out fault or alarm
functionality associated with the built-in port and 2) the Local/Remote functionality is such that the local
port loses control when in REMOTE mode. The local Ethernet port is used to serve web pages stored
on the SD card, and provides MODBUS TCP communications, as well as several utility functions for the
1050.
The local Ethernet port (J9) is an 8 pin inverted Ethernet jack. The receptacle accepts standard Ethernet
cable with 8P8C modular connectors. The standard configuration of the local Ethernet port is 100BaseT,
Full-Duplex, for use in communicating with the Spang LDC on a point-to-point isolated network. If the
Spang PCU will be part of a network by connecting through a standard Ethernet switch, the port can be
configured to Auto-negotiate network parameters with other intelligent devices. To change the network
connection behavior of the power controller, the TCPIPCFG.txt file on the SD memory card must be
edited using a computer, micro SD card reader and a standard text editor. The procedure is outlined in
the Configuration section of this manual.
Both the built-in and an add-on network option may be utilized at the same time, noting that one or the
other will have write access (both may read data) based on the REMOTE or LOCAL state.

Integrated Communication Protocol MODBUS TCP
MODBUS TCP is a vendor-neutral industrial communication protocol serving the application layer (level
7) of the OSI model. MODBUS TCP uses the Ethernet network and TCP/IP protocol to transfer
messages between intelligent devices. The MODBUS TCP protocol is a query/response or master/slave
protocol. The 1050 acts as a slave in the MODBUS master/slave relationship, with multiple masters
accommodated in a last-write wins mode.
MODBUS uses the reserved system port 502 on the TCP/IP stack for communication. If communication
to the slave cannot be established, the culprit may be a firewall (either running on the computer or on a
router) that blocks this port.
TCP/IP protocols depend on the IP address (the Integrated IP Address) to identify and communicate
with devices on the network. MODBUS TCP uses the IP address as the fundamental identifier for a
device. Devices on the network must have unique IP addresses, and in general should share the same
segment address for industrial functional groups (all devices on a particular machine, for example).
Network Communication Options July 2013
6-2
The integrated MODBUS TCP protocol implements no network timeout, and no network loss option.
The Spang 1050 products support the following MODBUS TCP function codes: FC 3 (Read Multiple
Registers), FC 6 (Write Single Register), FC 16 (Write Multiple Registers), and FC 23 (Write, then Read
Multiple Registers).
All 1050 settings can be read; all settings below 512 can be written by the master. Each register equals
16 bits (one word). Some settings of the 1050 require 2 contiguous registers. The Spang 1050 products
do NOT use zero based addressing; the MODBUS address is equivalent to the 1050 setting number.
Message Header
The Open MODBUS TCP Standard defines the 6-byte message header that precedes each
request/response. The header includes a 2-byte transfer reference (used by the master), 2-byte protocol
identifier, and a 2-byte length field.
The MODBUS TCP protocol requires no CRC or LRC checksum. The transport and link layer checksum
mechanisms are used to verify accurate message delivery.

Table 6-1 MODBUS TCP Message Header
Byte Field Description
1 Transaction Identifier (high)

For master use only; Slave echoes this byte
2 Transaction Identifier (low)

For master use only; Slave echoes this byte
3 Protocol Identifier (high) always 0
4 Protocol Identifier (low) always 0
5 Length, in bytes (high) always 0, because the body of the msg <= 250
6 Length, in bytes (low) number of bytes to follow in the message body

July 2013 Network Communication Options
6-3
Read Multiple Registers (FC 3)
The Read Multiple Registers function is used to read a contiguous block of 16-bit memory from the 1050.
The Read Multiple Registers request is sent from the master to the 1050 (slave).
The request specifies the starting address (the 1050 setting) and number of 16-bit registers to be read.
Note that a single 32-bit 1050 setting requires two (2) 16-bit registers of data. The Open MODBUS TCP
Standard sets the maximum message size at 256 bytes; therefore, the maximum number of 16-bit
memory locations that can be read is 125.
The request/response message body (bytes following the header) is described below.

Table 6-2 Read Multiple Registers request (FC 3)
1 Unit Identifier

Any valid MODBUS address.
2 Function Code MODBUS function code 3 (read multiple reg).
3 Start Register (high) High byte of 1050 setting number
4 Start Register (low) Low byte of 1050 setting number
5 Size N (high) Number of 16-bit registers to read (high byte)
6 Size N (low) Number of 16-bit registers to read (low byte)
each register is one 16 bit word

The normal response includes two bytes of data per register read. For each register, the first byte
contains the high order bits and the second contains the low order bits.
Table 6-3 Read Multiple Registers response
1 Unit Identifier

Echo MODBUS address sent.
2 Function Code MODBUS function code 3 (read multiple reg).
3 Byte count 2xN Number of data bytes to follow (2 X size from
request)
4 (byte
count + 4)
Data 16-bit values, high byte first

6-4
Write Single Register (FC 6)
The Write Single Register function is used to write a single 16-bit value to a memory location (register) in
the slave device. The request is sent from the master to the 1050 (slave).
The request specifies the starting address (in this case, the 1050 setting) and two bytes of data to be
written, high byte first.
Table 6-4 Write Single Register request (FC 6)
1 Unit Identifier

2 Function Code MODBUS function code 6 (write single register).
5 DataHi High byte of 16-bit value to be written.
6 DataLo Low byte of 16-bit value to be written.

The normal response is an echo of the request, returned after the data has been written.
Table 6-5 Write Single Register response
1 Unit Identifier

2 Function Code MODBUS function code 6 (write single register).
5 DataHi High byte of 16-bit value written (echo).
6 DataLo Low byte of 16-bit value written (echo).

6-5
Write Multiple Registers (FC 16)
The Write Multiple Registers function is used to write 16-bit values to a contiguous block of memory
(registers) in the 1050. The request is sent from the master to the 1050 slave. The message is of
variable length, depending on the amount of data to be written. The Open MODBUS TCP Standard sets
the maximum message size at 256 bytes; therefore, the maximum number of 16-bit memory locations
that can be written is 123.
The request specifies the starting address (in this case, the 1050 setting) and two bytes of data for each
16-bit location to be written, high byte first. Note that each 32-bit 1050 setting requires two (2) 16-bit
registers (4 bytes) of data. The message body (bytes following the header) is described below.
Table 6-6 Write Multiple Registers request (FC 16)
1 Unit Identifier

2 Function Code MODBUS function code 16 (write multiple reg).
5 Size N (high) Number of 16-bit registers to write (high byte)
6 Size N (low) Number of 16-bit registers to write (low byte)
7 Byte Count 2xN Number of bytes to follow (2 x size)
8 - (2xN+8) Data 16-bit values to be written, high byte first

The normal response sent from the 1050 contains the function code, starting address, and number of 16-
bit values (registers) written.
Table 6-7 Write Multiple Registers response
1 Unit Identifier

2 Function Code MODBUS function code 16 (write multiple reg).
3 Start register (high) High byte of 1050 setting number
4 Start register (low) Low byte of 1050 setting number
5 Size N (high) Number of 16-bit registers written (high byte)
6 Size N (low) Number of 16-bit registers written (low byte)
6-6
Write, then Read Multiple Registers (FC 23)
The Write Multiple Registers function performs a combination of one read operation and one write
operation in a single MODBUS transaction. The write operation is performed before the read. The
request is sent from the master to the 1050 slave.
The request specifies the starting address and number of registers to be read; the starting address and
number of registers to be written; the byte count (number of bytes to follow in the write data field);
followed by the data to be written.

Table 6-8 Read/Write Multiple Registers request (FC 23)
1 Unit Identifier

2 Function Code MODBUS function code 23 (read/write multiple
registers).
3 Read Start Register High byte of 1050 read setting
4 Read Start Register Low byte of 1050 read setting
5 Size NR (high) Number of 16-bit registers to read (high byte)
6 Size NR (low) Number of 16-bit registers to read (low byte)
3 Write Start Register High byte of 1050 write setting
4 Write Start Register Low byte of 1050 write setting
5 Size NW (high) Number of 16-bit registers to write (high byte)
6 Size NW (low) Number of 16-bit registers to write (low byte)
7 Byte Count 2xN Number of bytes to follow (2 x size NW)
8 (byte
count + 8)
Data 16-bit data to be written, high byte first

6-7
The normal response sent from the 1050 is of variable length. It returns the function code, number of
bytes read, followed by the 16-bit data values, high byte first.

Table 6-9 Read/Write Multiple Registers response
1 Unit Identifier

2 Function Code MODBUS function code 23 (read/write multiple
registers).
3 Byte count 2xNR Number of data bytes to follow (2 X size NR
from request)
4 (byte
count + 4)
Data... 16-bit values, high byte first

6-8
Read/Write Multiple Registers (FC 23) Example
The following example is a request to read 1050 setting numbers 520 (Remote Current), 522 (Voltage
Out), and 524 (Alarm Bits), and to write the Voltage Setpoint (setting 18).
The settings to be read are contiguous in 1050 memory and require 32 bits each (4 bytes). The setting
to be written requires 32 bits (4 bytes).

Table 6-10 Read/Write Multiple Registers Example
Request Response
Field Name (Hex) Field Name (Hex)
Unit Identifier

hh Unit Identifier (echo)

hh
Function Code 23 0x17 Function Code 23 0x17
Read Start Setting Hi (520 = 208 Hex) 02 Read Byte Count (2x6 registers =12) 0C
Read Start Setting Lo 08 Read Data Hi (setting 520, byte 4) hh
Number of Registers to Read Hi 00 Read Data Lo (setting 520, byte 3) hh
Number of Registers to Read Lo 06 Read Data Hi (setting 520, byte 2) hh
Write Start Setting Hi (18 = 12 Hex) 00 Read Data Lo (setting 520, byte 1) hh
Write Start Setting Lo 12 Read Data Hi (setting 522, byte 4) hh
Number of Registers to Write Hi 00 Read Data Lo (setting 522, byte 3) hh
Number of Registers to Write Lo 02 Read Data Hi (setting 522, byte 2) hh
Write Byte Count (2x2 registers = 4) 04 Read Data Lo (setting 522, byte 1) hh
Write Data Hi (MSB) hh Read Data Hi (setting 524, byte 4) hh
Write Data Lo hh Read Data Lo (setting 524, byte 3) hh
Write Data Hi hh Read Data Hi (setting 524, byte 2) hh
Write Data Lo hh Read Data Lo (setting 524, byte 1) hh

6-9
Exception Response
If, during a transaction, an error occurs, the normal response will not be sent by the 1050. A MODBUS
exception response is returned.
The exception response is of fixed length, with bit 7 of the function code byte set ON, and a single byte
following the function code with the 'exception code' or reason.
An exception response will be issued if an unsupported function is requested by the master, or if a
read/write request is out of range (Read registers range from 0 to 1023, write registers range from 0 to
511). Note that not all registers have an actual setting assigned in a particular 1050 power control unit.
The exception response message body (bytes following the header) is described below.

Table 6-11 MODBUS Exception Response
Byte Field Name Description
1 Address Echo MODBUS address sent.
2 Function + 0x80 MODBUS function code plus exception
indication (80 hex).
3 Exception code MODBUS exception code.

The 1050 power control products support the following MODBUS exception codes.

Table 6-12 MODBUS Exception Codes
Exception Code Description
01 Illegal function (function code not supported)
02
Illegal data address (setting number out of range; or
setting number + number of registers out of range).
03
Illegal data value (number of registers out of range; or
byte count <> 2x number of registers)

6-10
PLC Considerations
For most Modicon-like masters, reading and writing registers is done in the decimal 400xxxx address
range.
The 1050 products do not use zero based addressing, which is a legacy from early MODBUS
addressing. The MODBUS register address is equivalent to the 1050 setting number. For example, the
1050 Status setting (512) is referenced as 400512 (the number of zeroes depends on the PLCs
addressing scheme).
Settings that are 2 registers (32 bits) wide are read/written using Little Endian notation.

Table 6-13 Little Endian Notation
Request Response
Field Name (Hex) Field Name (Hex)
Function Code 03 0x03 Function Code 03 0x03
Read Start Register Hi 02 Read Byte Count (2x2 registers =4) 04
Read Start Register Lo (register =512) 00 Read Data Hi (register = 512, *Byte 2) hh
Number of Registers to Read Hi 00 Read Data Lo (*Byte 1) hh
Number of Registers to Read Lo 02 Read Data Hi (register = 513, *Byte 4) hh
Read Data Lo (*Byte 3) hh

*B4 = bits 31-24 *B3 = bits 23-16 *B2 = bits 15-8 *B1 = bits 7-0

6-11
Industrial Network Communication
Using the optional Spang industrial network interface, the 1050 power control product can be added to a
physical network of connected industrial devices, such as DeviceNet, PROFIBUS, or industrial Ethernet
(Ethernet/IP, PROFINET, or Ethernet MODBUS/TCP). The 1050 is defined as a slave (or server) device
for industrial networking purposes. As a slave device, the 1050 can be monitored and controlled by a
master device on the network.

DANGER

Only qualified electrical personnel familiar with the construction and operation of this
of life.
Caution

Incorrect configuration of the network interface may cause undesirable operation.

Network Interface Configuration
In order to communicate across a network, the 1050 network interface must be configured and added
(commissioned) as a node on the network.
Configuration of the 1050 network interface involves the setup of the Network Communication Map,
network address, network Baud Rate (if applicable), and Network Loss Option. Configuration is
accomplished, under local control, using the 1050 Configuration Tool application.
Node commissioning refers to the process of adding the 1050 unit, as a slave, to the network. Node
commissioning is accomplished using the actual physical network connection and the master device.
Note: Please refer to the associated Spang network manual for detailed instructions regarding network
operating parameters and address assignment.

6-12
Network Settings
On the Main form of the Configuration application, select the Network tab.

The Setup section contains the general network settings, including address, Network Loss Option,
timeout, and baud rate (DeviceNet only).
Assign a unique network address for each device on the network.
In the case of a DeviceNet network, set the baud rate to match the operating characteristics of the
network.
Note: Use caution when altering the DeviceNet Baud Rate of the 1050 network interface. If the
1050 Baud Rate does NOT match the network baud rate, network disruption may result.
Note: After changing the network address or DeviceNet Baud Rate setting, the 1050 unit must be
reset or have power cycled.
6-13
Set the Network Loss Option for desired operation. The Network Loss Option defines 1050 behavior
in the event that communication over the network is lost:

FAULT and STOP The 1050 unit will indicate a fault condition and the output will be shut off.
IGNORE and RUN There is no indication of network loss, and the 1050 continues normal operation.
ALARM and RUN The 1050 will indicate an alarm condition and continue normal operation.

The Number of Outputs describes the number of 1050 settings addressed by the IO exchange request
from master to slave (data WRITTEN TO the 1050). Since each output requires 4 bytes of data, the
Output Size is equal to the Number of Outputs x 4 (bytes). Note that the Control Word is included
in the number of Outputs and the Output Size. Outputs 2-10, if included in the IO request, are
assignable. For each Output defined in the IO request other than Output #1, there is a corresponding
1050 Poll Write setting in the Network Map.
The Number of Inputs describes the number of 1050 settings referenced in the IO exchange response
(from 1050 to master). Since each input requires 4 bytes of data, the Input Size is equal to the number
of inputs x 4 (bytes). Note that the Status Word is included in the number of Inputs and the Input
Size. Inputs 2-10, if included in the IO response, are assignable. For each Input defined in the IO
response other than Input #1, there is a corresponding 1050 Poll Read setting in the Network Map.

6-14
Network Map
The Network Map is the blueprint describing the data exchanged between master and slave.
The Network tab, Map section allows the assignment of up to nine 1050 settings as inputs, and up to nine
1050 settings as outputs.

6-15
Table 6-14 Output Assembly - Poll Write Reference
1050 Setting and Name Output Assembly Ref Default Assignment
na Output #1 Setting 2 Control Word (ALWAYS)
233 Poll Write #2 Output #2 0 - unused
... ... ...

The Value column on the Network Map tab reflects the name of the assigned 1050 setting. Note that
output assignments must be writable; if the assigned setting is read-only, the corresponding data in
the write request will not be written to the 1050 unit.
It is important to note that the data in the IO exchange (write) request is written to the 1050 with
every polled IO exchange. Therefore, the output data must be maintained. For this reason, Spang
recommends that outputs be used for setpoints only.
Table 6-15 Input Assembly - Poll Read Reference
1050 Setting and Name Input Assembly Ref Default Assignment
na Input #1 Setting 512 Status Word (ALWAYS)
223 Poll Read #2 Input #2 0 - unused

6-16

7-1
Chapter 7
Settings
Caution

The 1051 is configured using the programmable settings. Programming the settings
incorrectly can cause the 1051 to exhibit intermittent or full output conditions.

Table 7-1 List of Settings
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Control
Write Access: All
Default: 0x00000400
2 0
FFFFFFFF
(hex)
Unsigned
32 bits
Control information acted on by the unit.
Bits are defined as follows:
bit 0 Output On/Off (maintained)
0 = Off
1 = On
bit 1 Fault Reset (momentary)
0 = no action
1 = initiate fault reset
bit 2 (reserved)
bit 3 Clear Fault History (momentary)
0 = no action
1 = initiate Clear
bit 4 Clear Alarm History
(momentary)
0 = no action
1 = initiate Clear
bit 5 Feed Forward (maintained)
0 = Off
1 = On
bits 6 8 (reserved)
bit 9 Auto Offset A/D
0 = no action
1 = active
bit 10 PING (maintained)
0 = passive
1 = active
bits 11 31 (reserved)
Settings July 2013
7-2
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Voltage Input Rating
Write Access: Off
Default: 480.0
4 0.1 1000.0 Unsigned
32 bits
Vrms
The line-to-line voltage input rating of
the voltage supplied to the SCRs.
Voltage Input High Fault
Write Access: All
Default: 600.0
6 0 3500.0 Unsigned
32 bits
Vrms
The level compared to Vin
rms
that
causes a high voltage fault.
Voltage Input Low Limit
Write Access: All
Default: 384.0
8 0 1000.0 Unsigned
32 bits
Vrms
The level compared to Vin
rms
that
causes a low voltage fault/alarm
Voltage Output Rating
Write Access: Off
Default: 480.0
10 0.1 1000.0 Unsigned
32 bits
Vrms
The line-to-line voltage output rating of
the voltage supplied from the SCRs.
Initial Pulse
Write Access: Off
Default: 100.0
12 0 100.00 Unsigned
16 bits
%
For a transformer load under zero cross
control: the delay in the firing of the
SCRs during the first cycle of each
burst. The setting is expressed as the
percentage of the total wave passed
through to the load. For direct coupled
loads, this setting should be 100%.
Magnetizing Ramp
Write Access: Off
Default: 1
13 1 100 Unsigned
16 bits

For soft start of a transformer load under
zero cross control:
the number of phase control cycles
which will occur during the first on cycle
of zero cross control. A minimum
setting of 3 will usually keep the inrush
current within acceptable limits. For
direct coupled loads, this setting should
be 1.
Firing Mode
Write Access: All
Default: 0
14 0 -- 1 Unsigned
16 bits
Selection
0 Phase Angle
1 Zero Cross
July 2013 Settings
7-3
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Automatic Power Sync
Mode
Write Access: Off
Default: 0
15 0 -- 1 Unsigned
16 bits
Selection
In zero-cross mode, automatically
distribute firing of individual units over
time so that peak power usage is
minimized.
0 Off
1 On
Analog Track and Hold
Write Access: All
Default: 0
16 0 -- 1 Unsigned
16 bits
Selection
The ability of the controller to hold at the
last internal analog setpoint if/when
analog input signal loss is detected.
Analog input signal loss is defined as
the analog input signal falling below
3mA.
0 Off
1 On
Voltage Output Setpoint
Write Access: All
Default: 480.0
32 bits
Vrms
The setpoint for the voltage output PID
control. It is limited to 200% of the
Voltage Output Rating or the Voltage
Setpoint Limit whichever is lower (or
make same as current setpoint setting
42).
Voltage Setpoint Limit
Write Access: All
Default: 480.0
32 bits
Vrms
The maximum voltage the voltage
output PID control will limit to. It is
limited to 200% of the Voltage Output
Rating.
Voltage Output
Proportional Gain
Write Access: All
Default: 10.00
22 .01 100.00 Unsigned
16 bits
%
Voltage output control proportional gain.
Voltage Output Integral
Gain
Write Access: All
Default: 10.00
23 .01 100.00 Unsigned
16 bits
%
Voltage output control integral gain.
Voltage Output
Derivative Gain
Write Access: All
Default: 0
16 bits
%
Voltage output control derivative gain.
Settings July 2013
7-4
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Voltage Feed Forward
Control
Write Access: All
Default: 0.00
16 bits
%
Amount of additional duty cycle control
applied for fast initial response, but also
allowing relaxed PID values (soft, lazy
control). *** This feature is NOT
intended for normal SCR operation;
contact Spang Power Electronics for
further information.
Current Input Rating
Write Access: Off
Default: 350.0
26 1.0 10000.0 Unsigned
32 bits
Arms
The rating of the current flowing through
the SCRs.
Current Input Limit
Write Access: All
Default: 350.0
28 1.0 10000.0 Unsigned
32 bits
Arms
The maximum input current; if
exceeded, it will limit the duty cycle of
the unit and cause an Input Current
Limit alarm.
Tap Change Low Alarm
Write Access: All
Default: 0.00
16 bits
%
The lower limit of the Duty Cycle
Output. An alarm will be indicated for a
Duty Cycle Output below this level.
Note: A value of zero (0) is off; ie, no
alarm annunciated.
Remote Current Rating
Write Access: Off
Default: 350.0
34 1.0
100000.0
Unsigned
32 bits
Arms
The output current rating when remote
feedback (option board) is used.
Current High Fault
Retry Number
Write Access: All
Default: 0
36 0 6 Unsigned
16 bits
The number of restart attempts on a
Current High Fault before the fault is
latched.
Current High Fault
Retry Time
Write Access: All
Default: 10
37 1 360 Unsigned
16 bits
Sec
The delay time period after which the
unit will attempt to restart following an
overcurrent shutdown.
July 2013 Settings
7-5
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Current High Fault
Ratio to Rating
Write Access: All
Default: 125.00
16 bits
%
The overcurrent trip level expressed as
a percentage of the Current Rating. If
the Current Input Rating is 350.0A, and
the Current High Fault Ratio to Rating is
125%, then the high current trip level is
350.0 * 1.25 = 437.5Arms. Trip level will
be based on peak value (RMS
value*sqrt(2))
Current Setpoint
Write Access: All
Default: 300.0
42 0 10000.0 Unsigned
32 bits
Arms
The setpoint for the current output PID
control; it is limited to the value of the
Current Setpoint Limit.
Current Setpoint Limit
Write Access: OFF
Default: 300.0
44 0 10000.0 Unsigned
32 bits
Arms
The maximum current for the current
output PID control. It is limited to 200%
of the Current Output Rating.
Current Output
Proportional Gain
Write Access: All
Default: 10.00
46 .01 100.00 Unsigned
16 bits
%
Current output control proportional gain.
Current Output Integral
Gain
Write Access: All
Default: 10.00
47 .01 100.00 Unsigned
16 bits
%
Current output control integral gain.
Current Output
Derivative Gain
Write Access: All
Default: 0.00
16 bits
%
Current output control derivative gain.
Current Feed Forward
Control
Write Access: All
Default: 0.00
16 bits
%
Amount of additional current control
Settings July 2013
7-6
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Duty Cycle Setpoint
Write Access: All
Default: 10.00
16 bits
%
The setpoint for open loop control.
Power Setpoint
Write Access: All
Default: 5000.0
52 0.0
1,000,000.0
Unsigned
32 bits
KW
The setpoint for the power output PID
control. It is limited to 100% of the
Power Setpoint Limit.
Sync Group Power
Rating
Write Access: Off
Default: 100 000.0
54 0.0
1,000,000.0
Unsigned
32 bits
KW
The sum of the power ratings of the
105x units in the analog current loop.
Power Setpoint Limit
Write Access: All
Default: 5000.0
58 0.0
1,000,000.0
Unsigned
32 bits
KW
The maximum power the power output
PID control will limit to. It is limited to
200% of the Power Rating.
Power Output
Proportional Gain
Write Access: All
Default: 10.00
60 .01 100.00 Unsigned
16 bits
%
Power output control proportional gain.
Power Output Integral
Gain
Write Access: All
Default: 10.00
61 .01 100.00 Unsigned
16 bits
%
Power output control integral gain.
Power Output
Derivative Gain
Write Access: All
Default: 0
62 0.00 100.00 Unsigned
16 bits
%
Power output control derivative gain.
Power PID Feed
Forward
Write Access: All
Default: 0.00
16 bits
%
Amount of additional power control
July 2013 Settings
7-7
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Thermocouple Offset
Write Access: All
Default: 0
73 -10.0 to
+10.0
Signed
16 bits
DegC
Thermal scale offset
Cold Junction
Compensation

Write Access: All
Default: 0
74 0 1 Unsigned
16 bits
Selection
0 On
1 Off
Heatsink Temperature
High Alarm
Write Access: All
Default: 80.0
75 0 100.0 Unsigned
16 bits
DegC
The point after which the SCR heatsink
temperature (Setting #563) causes an
alarm condition.
High Fault
Write Access: All
Default: 100.0
76 0 120.0 Unsigned
16 bits
DegC
The point after which the SCR heatsink
temperature (Setting #563) causes a
fault condition, shutting down the 1051
output.
Ramp Up Time
Write Access: All
Default: 3
77 0 360.0 Unsigned
16 bits
Sec
The time it takes for the controlling
setpoint to rise from 0 to 100% of its
maximum.
Ramp Down Time
Write Access: All
Default: 3
78 0 360.0 Unsigned
16 bits
Sec
If the output is on, the time it takes for
the controlling setpoint to decrease from
100 to 0% of its rating. NOTE: An OFF
command stops the output immediately.
Enable Display Buttons
Write Access: All
Default: 1
80 0 1 Unsigned
16 bits
Selection
Enable/disable local control from the
LDC:
0 Disable Display Controls
1 Enable Display Controls
Frequency
Write Access: Off
Default: 0
81 0 1 Unsigned
16 bits
Selection
The input line frequency rating.
The selections are:
0 60 Hz
1 50 Hz
Settings July 2013
7-8
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Local Control Mode
Write Access: All
Default: 0
82 0 1 Unsigned
16 bits
Selection
The control type under local control.
The selections are:
0 Digital
1 Analog
Regulation Mode
Write Access: All
Default: 0
83 0 3 Unsigned
16 bits
Selection
Regulation mode selections:
0 Duty Cycle Control
1 Power Control
2 Current Output Control
3 Voltage Output Control
Low Voltage Operation
Write Access: All
Default: 0
84 0 1 Unsigned
16 bits
Selection
Low voltage action:
0 Alarm
1 Fault
Startup Operation
Write Access: All
Default: 0
85 0 1 Unsigned
16 bits
Selection
Startup Operation:
0 Normal
1 Automatic
Voltage Input Feedback
Range
Write Access: OFF
Default: 0
86 0 1 Unsigned
16 bits
Selection
Voltage range of the voltage fed back
from the input PT:
0 Low (240.0V)
1 High (240.0 to 600.0V)
Calibration Setpoint
Write Access: All
Default: 100.00
87 0.00 100.00 Unsigned
16 bits
%
Setting used to assign a known level
during analog calibration.
Current Date and Time
Write Access: All
Default: na
88 Unsigned
32 bits
Current date and time as kept in the
1050 unit (POSIX UTC time).
Time Zone (+/- GMT)
Write Access: All
Default: 16 (ET US)
90 0 23 Unsigned
16 bits
Selection
Time zone for the Local Display.
Voltage Output
Feedback Range
Write Access: OFF
Default: 0
92 0 1 Unsigned
16 bits
Selection
Voltage range of the voltage fed back
from the output PT:
0 Low
1 High
*see note at the end of this chapter
July 2013 Settings
7-9
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Feedback Source
Write Access: OFF
Default: 0
93 0 1 Unsigned
16 bits
Selection
Feedback used for control (voltage and
current):
0 Local Feedback
1 Remote Feedback
Digital Output #1
Selection
Write Access: All
Default: 0
97 0 11 Unsigned
16 bits
Selection
Digital Output configuration selections:
0 not used
1 Run
2 Fault
3 Alarm
4 Fault or Alarm
5 Filtered Alarm
6 OK to Run
7 No Fault
8 Local Control Analog
9 Local Control Digital
10 Firing Mode Phase Angle
11 Firing Mode Zero Cross
Digital Output #2
Selection
Write Access: All
Default: 0
98 0 11 Unsigned
16 bits
Selection
Same selections as Digital Output #1
Selection
Digital Output #3
Selection
Write Access: All
Default: 0
99 0 11 Unsigned
16 bits
Selection
Selection
Relay Output Selection
Write Access: All
Default: 0
100 0 11 Unsigned
16 bits
Selection
Selection
Analog Output #1
Selection
Write Access: All
Default: 0
101 0 6 Unsigned
16 bits
Selection
Analog Output configuration selections:
0 Output Power
1 Voltage Output
2 Current Output
3 Duty Cycle Output
4 Calibration Setpoint
5 Process Temperature
6 Sync Power Usage
Settings July 2013
7-10
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Analog Output #2
Selection
Write Access: All
Default: 0
102 0 6 Unsigned
16 bits
Selection
Same selections as Analog Output #1
Selection
Analog Output #3
Selection
Write Access: All
Default: 0
103 0 6 Unsigned
16 bits
Selection
Selection
Analog Output #4
Selection
Write Access: All
Default: 0
104 0 6 Unsigned
16 bits
Selection
Selection
Analog Output #5
Selection
Write Access: All
Default: 0
105 0 6 Unsigned
16 bits
Selection
Selection
Analog Output #6
Selection
Write Access: All
Default: 0
106 0 6 Unsigned
16 bits
Selection
Selection
Analog Reference #1
Selection
Write Access: All
Default: 0
113 0 8 Unsigned
16 bits
Selection
Analog Reference configuration
selections:
0 not used
1 Voltage Output Setpoint
2 Current Output Setpoint
3 Power Output Setpoint
4 Duty Cycle Setpoint
5 Process Temperature Setpoint
6 Process Temperature Feed
Forward
7 Sync Group Power Sense
8 Regulation Mode Setpoint
Analog Reference #2
Selection
Write Access: All
Default: 0
114 0 8 Unsigned
16 bits
Selection
Same selections as Analog Reference
#1 Selection
July 2013 Settings
7-11
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Voltage Input Zero
Write Access: All
Default: 0
120 0 -- 65535 Unsigned
16 bits
Digital zero suppression level of the
voltage signal.
Voltage Input Offset
Read Only
121 -2048 to
2048
Signed
16 bits
DSP calculated scale centering factor.
Voltage Input Gain
Write Access: All
Default: 10000
122 .01-12.0 Float
32 bits
Digital span adjustment of the voltage
signal.
Voltage Output Zero
Write Access: All
Default: 0
124 0 -- 65535 Unsigned
16 bits
voltage signal.
Voltage Output Offset
Read Only
125 -2048 to
2048
Signed
16 bits
Voltage Output Gain
Write Access: All
Default: 20000
126 .01-12.0 Float
32 bits
Digital span adjustment of the voltage
signal.
Current Input Zero
Write Access: All
Default: 0
128 0 -- 65535 Unsigned
16 bits
voltage signal.
Current Input Offset
Read Only
129 -2048 to
2048
Signed
16 bits
Current Input Gain
Write Access: All
Default: 20000
130 .01-12.0 Float
32 bits
Digital span adjustment of the current
signal.
Remote Current Zero
Write Access: All
Default: 0
132 0 -- 65535 Unsigned
16 bits
voltage signal.
Remote Current Offset
Read Only
133 -2048 to
2048
Signed
16 bits
Settings July 2013
7-12
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Remote Current Gain
Write Access: All
Default: 20000
134 .01-12.0 Float
32 bits
Digital span adjustment of the current
signal.
Analog Reference #1
Offset
Write Access: All
Default: 0
137 -32767 to
32767
Signed
16 bits
Zero offset eg. 4 mA = 0 for 4-20mA
signals.
Analog Reference #1
Gain
Write Access: All
Default: 20000
138 .01-12.0 Float
32 bits
Digital scale factor, typically used to set
the 100% level.
Analog Reference #2
Offset
Write Access: All
Default: 0
141 -32767 to
32767
Signed
16 bits
signals.
Analog Reference #2
Gain
Write Access: All
Default: 20000
142 .01-12.0 Float
32 bits
Digital scale factor, typically used to set
the 100% level.
Thermocouple Type
Write Access: Off
Default: 0
148 0 7 Unsigned
16 bits
Selection
0 none
1 Type J
2 Type K
3 Type R
4 Type S
5 Type E
6 Type T
Analog Output #1 Offset
Write Access: All
Default: 0
206 -10000 to
10000
Signed
16 bits
signals.
Analog Output #1 Span
Write Access: All
Default: 20000
207 1000 30000 Unsigned
16 bits
Digital span adjustment of the analog
output
July 2013 Settings
7-13
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Write Access: All
Default: 0
208 -10000 to
10000
Signed
16 bits
signals.
Write Access: All
Default: 20000
209 1000 30000 Unsigned
16 bits
output
Write Access: All
Default: 0
210 -10000 to
10000
Signed
16 bits
signals.
Write Access: All
Default: 20000
211 1000 30000 Unsigned
16 bits
output
Write Access: All
Default: 0
212 -10000 to
10000
Signed
16 bits
signals.
Write Access: All
Default: 20000
213 1000 30000 Unsigned
16 bits
output
Write Access: All
Default: 0
214 -10000 to
10000
Signed
16 bits
signals.
Write Access: All
Default: 20000
215 1000 30000 Unsigned
16 bits
output
Write Access: All
Default: 0
216 -10000 to
10000
Signed
16 bits
signals.
Write Access: All
Default: 20000
217 1000 30000 Unsigned
16 bits
output
Settings July 2013
7-14
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Number of Outputs
Write Access: All
Default: 10
221 1 10 Unsigned
16 bits
Network Poll Block: the number of 32-
bit values to be WRITTEN to the 1051
by the master device.
Number of Inputs
Write Access: All
Default: 10
222 1 10 Unsigned
16 bits
Network Poll Block: the number of 32-
bit values to be READ by the master
device from the 1051.
Poll Read #2 Setting
Write Access: All
Default: 512
223 0 1023 Unsigned
16 bits
The 1051 setting to be read as Input #2
of the network poll message.
Write Access: All
Default: 512
224 0 1023 Unsigned
16 bits
Write Access: All
Default: 512
225 0 1023 Unsigned
16 bits
Write Access: All
Default: 512
226 0 1023 Unsigned
16 bits
Write Access: All
Default: 512
227 0 1023 Unsigned
16 bits
Write Access: All
Default: 512
228 0 1023 Unsigned
16 bits
Write Access: All
Default: 512
229 0 1023 Unsigned
16 bits
Write Access: All
Default: 512
230 0 1023 Unsigned
16 bits
July 2013 Settings
7-15
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Write Access: All
Default: 512
231 0 1023 Unsigned
16 bits
The 1051 setting to be read as Input
#10 of the network poll message.
Poll Write #2 Setting
Write Access: All
Default: 0
233 0 1023 Unsigned
16 bits
The 1051 setting to be written as
Output #2 of the network poll message.
Write Access: All
Default: 0
234 0 1023 Unsigned
16 bits
Write Access: All
Default: 0
235 0 1023 Unsigned
16 bits
Write Access: All
Default: 0
236 0 1023 Unsigned
16 bits
Write Access: All
Default: 0
237 0 1023 Unsigned
16 bits
Write Access: All
Default: 0
238 0 1023 Unsigned
16 bits
Write Access: All
Default: 0
239 0 1023 Unsigned
16 bits
Write Access: All
Default: 0
240 0 1023 Unsigned
16 bits
Write Access: All
Default: 0
241 0 1023 Unsigned
16 bits
Output #10 of the network poll
message.
Settings July 2013
7-16
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Poll Write #1 Value
Write Access: All
Default: na
242 0
FFFFFFFF
Unsigned
32 bits
Binary
The value received from the PLC for
Write Output #1. Output #1 is mapped
to the Control Word (setting 2).
Poll Write #2 Value
Write Access: All
Default: na
244 -7FFFFFFF
to 7FFFFFFF
Signed
32 bits
Write Output #2.
Poll Write #3 Value
Write Access: All
Default: na
246 -7FFFFFFF
to 7FFFFFFF
Signed
32 bits
Write Output #3.
Poll Write #4 Value
Write Access: All
Default: na
248 -7FFFFFFF
to 7FFFFFFF
Signed
32 bits
Write Output #4.
Poll Write #5 Value
Write Access: All
Default: na
250 -7FFFFFFF
to 7FFFFFFF
Signed
32 bits
Write Output #5.
Poll Write #6 Value
Write Access: All
Default: na
252 -7FFFFFFF
to 7FFFFFFF
Signed
32 bits
Write Output #6.
Poll Write #7 Value
Write Access: All
Default: na
254 -7FFFFFFF
to 7FFFFFFF
Signed
32 bits
Write Output #7.
Poll Write #8 Value
Write Access: All
Default: na
256 -7FFFFFFF
to 7FFFFFFF
Signed
32 bits
Write Output #8.
Poll Write #9 Value
Write Access: All
Default: na
258 -7FFFFFFF
to 7FFFFFFF
Signed
32 bits
Write Output #9.
Poll Write #10 Value
Write Access: All
Default: na
260 -7FFFFFFF
to 7FFFFFFF
Signed
32 bits
Write Output #10.
July 2013 Settings
7-17
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
DeviceNet Address
Write Access: All
Default: 63
264 1 63 Unsigned
16 bits
For the DeviceNet network type,
defines the network node address.
PROFIBUS Address
Write Access: All
Default: 126
265 1 126 Unsigned
16 bits
For the PROFIBUS network type,
defines the network node address.
Network Loss Option
Write Access: All
Default: 2
266 0 2 Unsigned
16 bits
Selection
Defines the action taken by the 1051
control in the event of a network loss.
The selections are:
0 Fault and Stop
1 Alarm and Run
2 Ignore and Run
DeviceNet Baud Rate
Write Access: All
Default: 2
267 0 2 Unsigned
16 bits
Selection
The network baud rate for the
DeviceNet network type. The
selections are:
0 125 Kilo Baud
1 250 Kilo Baud
2 500 Kilo Baud
Ethernet Network
Timeout
Write Access: All
Default: 250
275 10 65535 Unsigned
16 bits
mSec
For network type = Ethernet, the amount
of time passing without an incoming
message from a MODBUS/IP master
before the unit will consider the network
lost. Unit behavior at this point is
determined by the Network Loss
setting.
Ethernet Address
Write Access: All
Default: 1
276 4 octets,
each having
the value 0
255
For optional industrial network type =
Ethernet, the units IP address.

Redundant Ethernet
Address
Write Access: All
Default: 1
278 4 octets,
each having
the value 0
255
Reserved for redundant network
implementation.
Settings July 2013
7-18
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Ethernet Gateway
Write Access: All
Default: 1
286 4 octets,
each having
the value 0
255
For network type = Ethernet, the IP
address of the network router, if used.
Redundant Ethernet
Gateway
Write Access: All
Default: 1
288 4 octets,
each having
the value 0
255
implementation.
July 2013 Settings
7-19
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
IP Subnet Mask
Write Access: All
Default:
290 4 octets,
each having
the value 0
255
Unsigned
16 bits
Selection
For network type = Ethernet, the mask
isolates addresses on the local
network. Addresses outside of the mask
will be referred to the gateway (handled
through the router).

000.000.000.000 0 mask bits
128.000.000.000 1 mask bit
192.000.000.000 2 mask bits
224.000.000.000 3 mask bits
240.000.000.000 4 mask bits
248.000.000.000 5 mask bits
252.000.000.000 6 mask bits
254.000.000.000 7 mask bits
255.000.000.000 8 mask bits
255.128.000.000 9 mask bits
255.192.000.000 10 mask bits
255.224.000.000 11 mask bits
255.240.000.000 12 mask bits
255.248.000.000 13 mask bits
255.252.000.000 14 mask bits
255.254.000.000 15 mask bits
255.255.000.000 16 mask bits
255.255.128.000 17 mask bits
255.255.192.000 18 mask bits
255.255.224.000 19 mask bits
255.255.240.000 20 mask bits
255.255.248.000 21 mask bits
255.255.252.000 22 mask bits
255.255.254.000 23 mask bits
255.255.255.000 24 mask bits
255.255.255.128 25 mask bits
255.255.255.192 26 mask bits
255.255.255.224 27 mask bits
255.255.255.240 28 mask bits
255.255.255.248 29 mask bits
255.255.255.252 30 mask bits
Settings July 2013
7-20
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Redundant IP Subnet
Mask
Write Access: All
Default: 1
291 0 30 Unsigned
16 bits
Selection
implementation.
Direct Write Digital
Outputs
Write Access: All
Default: 0
294 0 65535 Unsigned
16 bits

Direct manipulation of the bits assigned
to digital outputs.
Digital Input #0
Selection
Write Access: All
Default: 0
295 0 12 Unsigned
16 bits
Selection
Digital input configuration selections:
0 not used
1 Alarm when Closed
2 Alarm when Open
3 Fault when Closed
4 Fault when Open
5 Fault Reset
6 Output On
7 Timed Fault when Closed
8 Timed Fault when Open
9 Timed Alarm when Closed
10 Timed Alarm when Open
11 Local Control Mode = Analog
12 Firing Mode = Zero Cross
Digital Input #1
Selection
Write Access: All
Default: 0
296 0 12 Unsigned
16 bits
Selection
Same selections as Digital Input #0
Selection
Digital Input #2
Selection
Write Access: All
Default: 0
297 0 12 Unsigned
16 bits
Selection
Selection
Digital Input #3
Selection
Write Access: All
Default: 0
298 0 12 Unsigned
16 bits
Selection
Selection
July 2013 Settings
7-21
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Alarm Filter
Write Access: All
Default: 0
300 0 --
4294967295
Unsigned
32 bits

User-settable mask applied to the Alarm
Bits setting; the filter determines which
alarm bit(s) will trigger the Filtered
Alarm bit in the Status Word.
Process Temperature
Set Point
Write Access: All
Default: 200.0
350 0 4000.0 Unsigned
16 bit
DegC
Target temperature for the process
Process Temperature
Ramp Up
Write Access: All
Default: 60.0
351 1 6553.5 Unsigned
16 bit
DegC/Hr
Rate of set point change when
increased
Process Temperature
Ramp Down
Write Access: All
Default: 60.0
352 1 6553.5 Unsigned
16 bit
DegC/Hr
Rate of set point change when
decreased
Process Temperature
Set Point Limit
Write Access: All
Default: 4000.0
353 0 4000.0 Unsigned
16 bit
DegC
Maximum temperature set point equal to
100% value of analog control
Process Temp
Proportional Gain
Write Access: All
Default: 10.00
354 0 -100.00
Unsigned
16 bit
%
Digital span adjustment of the process
temperature proportional signal.
Process Temp Integral
Gain
Write Access: All
Default: 10.00
355 0 -100.00
Unsigned
16 bit
%
temperature integral signal.
Process Temp
Differential Gain
Write Access: All
Default: 0
356 0 -100.00
Unsigned
16 bit
%
temperature differential signal.
Process Temp
Anticipate Control
Write Access: All
Default: 0
357 0 -100.00
Unsigned
16 bit
%
temperature feed forward signal.
Settings July 2013
7-22
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Process Temperature
Control
Write Access: All
Default: 0
358 0 - 3 Unsigned
16 bit
selection
0 Not used
1 Monitor only
2 Control Temperature
3 Limit Temperature
Thermocouple Break
Action
Write Access: All
Default: 0
359 0 - 2 Unsigned
16 bit
selection
0 Ignore
1 Alarm
2 Fault
Process Temp High
Alarm
Write Access: All
Default: 4000.0
360 0 4000.0 Unsigned
16 bit
DegC
Alarm if above this value
Process Temp Low
Alarm
Write Access: All
Default: 4000.0
361 0 4000.0 Unsigned
16 bit
DegC
Alarm if below this value
Process Temp High
Fault
Write Access: All
Default: 4000.0
362 0 4000.0 Unsigned
16 bit
DegC
Fault if above this value
Process Temp High
Delayed Fault
Write Access: All
Default: 4000.0
363 0 4000.0 Unsigned
16 bit
DegC
Fault if above this value for longer than
Process Temp High Delay seconds
Process Temp High
Fault Delay
Write Access: All
Default: 60.0
364 0 6553.5 Unsigned
16 bit
Sec
Delay time for Process Temp High
Delayed Fault
Process Temp Control
Output
Write Access: All
Default: 0

366 0 100.00 Unsigned
16 bit
%
Output of the temperature PID loop (0-
100% equals 0 to the setpoint limit of the
chosen regulation mode)
July 2013 Settings
7-23
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Status
Read Only
512 0
FFFFFFFF
Unsigned
32 bits
Binary
bit 0 Output Off/On
0 = Output Off
1 = Output On
bit 1 Fault Status
0 = no fault
1 = Fault present
bit 2 Alarm Status
0 = no alarm
1 = Alarm present
bit 3 Local /Remote
0 = Local control
1 = Remote (network) control
bit 4 Inhibit/Enable
0 = Output Inhibited
1 = Output Enabled
bit 5 Analog/Digital
0 = Analog control
1 = Digital control
bit 7 Phase Lock
0 = no lock
1 = Phase Locked
bit 8 Ramp Status
0 = not at setpoint
1 = at setpoint
bit 9 Maximum Output Limit
0 = not at limit
1 = at limit
bit 10 Power Limit
0 = not at limit
1 = at limit
bit 11 Voltage Limit
0 = not at limit
1 = at limit
bit 12 Current Output Limit
0 = not at limit
1 = at limit
bit 13 Current Input Limit
0 = not at limit
1 = at limit
bit 14 Trip Retry
0 = not retrying
1 = retrying

Settings July 2013
7-24
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
bit 15 Firing Mode
0 = Phase Angle
1 = Zero Cross
bit 16 OK to Run
0 = na
1 = OK to Run
bit 17 Filtered Alarm
0 = no alarm
1 = Alarm
bit 18 Thermal Ramp
0 = na
1 = Ramp complete
bit 19 Thermal Limit
0 = na
1 = T Limit
bit 20 Ref #1 Wirebreak
0 = na
1 = Ref #1 Break
bit 21 Ref #2 Wirebreak
0 = na
1 = Ref #2 Break
bits 22 27 (reserved)
bit 28 DSP Firing SCRs
0 = off
1 = Firing
bit 29 Image Bit State (PING)
0 = passive
1 = active
bit 30 Device Heartbeat
(2 second cycle)
Fault Code
Read Only
514 0 to 30 Unsigned
16 bits
Currently existing fault condition.
Alarm Code
Read Only
515 100 to 135 Unsigned
16 bits
Highest priority existing alarm condition.
Note: Use the Alarm Status Bits
setting to view ALL existing alarms.
Voltage Input
Read Only
516 xxxxxxxx.x Signed
32 bits
Vrms
The input voltage to the SCR
July 2013 Settings
7-25
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Current Input
Read Only
32 bits
Arms
Built-in CT measured current value
Remote Current
Read Only
32 bits
Arms
Optional remotely sensed current
Voltage Output
Read Only
32 bits
Vrms
The resultant voltage at the load.
Settings July 2013
7-26
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Alarm Status Bits
Read Only
524 0 --
4294967295
Unsigned
32 bits
Decimal
Each bit represents an active alarm;
only the highest-priority active alarm is
reflected in the Alarm Code setting.
b0 (1) Overcurrent Retry
b1 (2) Output Current High
b2 (4) Network Loss
b3 (8) External Input #0
b7 (128) SCR High Temperature
b8 (256) Line frequency
b9 (512) Input Voltage Low
b10 (1024) Maximum Output
b11 (2048) Power Limit
b12 (4096) Voltage Limit
b13 (8192) Current Limit
b14 (16384) Current Input Limit
b15 (32768) Line Phase Lock Loss
b16 (65536) Time/Date not set
b17 (131072) Heatsink Temp High
b18 (262144) Heatsink Temp Sensor
b19 (524288) Retrying on Input
Overcurrent
b20 (1048576) Process Temp Limit
b21 (2097152) Process Temp High
b22 (4194304) Process Temp Low
b23 (8388608) Thermocouple Wirebreak
b24 (16777216) Reference #1
Wirebreak
b25 (33554432) Reference #2
Wirebreak
b26 (67108864) Tap Change Alarm
Controlled Current
Read Only
526 xxxxxxxx.x Unsigned
32 bits
Arms
Either the locally sensed or remote
current, depending on which is selected
for control.
Ratio of Unit Power
Rating to Group
Read Only
528 xxx.xx Unsigned
16 bits
%
Ratio in percentage of this units power
rating versus the Sync Group Power
Rating (setting #54)
July 2013 Settings
7-27
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Analog Output Used for
Sync
Read Only
529 xx Unsigned
16 bits
Analog output # of the output used in the
sync ring for Auto Sync Operation
Analog Input Used for
Sync
Read Only
530 xx Unsigned
16 bits
Analog reference # of the input used in
the sync ring for Auto Sync Operation
Group Power Reading
Read Only
532 xxxxxxxx Unsigned
32 bits
W
Total (instantaneous) power reading of
the ring
Duty Cycle Output
Read Only
538 xxx.xx Unsigned
16 bits
%
On time / off time *100.0
Power Factor
Read Only
540 x.xx Unsigned
16 bits
Power Actual / KVA Actual
Frequency Actual
Read Only
541 xxx.x Unsigned
16 bits
Hz
The input line frequency.
Power In
Read Only
32 bits
W
Power as calculated using the input
voltage and input current.
Note: All power-related settings are
transferred in Watts; Spang peripheral
devices format and display as KW.
Power Rating
Read Only
32 bits
W
The rating of the power being controlled.
It is calculated by the following equation.
Voltage Output Rating * Current
Output Rating
Remote Power
Read Only
32 bits
W
Power as calculated using the optional
remote voltage and remote current.
Settings July 2013
7-28
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Controlled Power
Read Only
32 bits
W
Either the locally sensed or remote
power, depending on selected control.
KVA Actual
Read Only
554 xxxxxxxx.x Unsigned
32 bits
KVA
(Voltage Input * Current Input)/1000
Custom Bits
558 0 -
FFFFFFFF
Unsigned
32 bits
Binary
(reserved)
Ramped Process
Temperature Setpoint
Read Only
562 xxxx.x Unsigned
16 bits
DegC
Setpoint value for temperature control
after the ramp is applied (input to PID
algorithm)
Read Only
563 xxxx.x Signed
16 bits
DegC
Temperature in degrees C of the
heatsink that the SCRs are mounted on.
Thermocouple
Temperature
Read Only
564 xxxx.x Signed
16 bits
DegC
Reading from the optional thermocouple
sense also known as Process
Temperature
Option Board
Temperature
Read Only
565 xxxx.x Signed
16 bits
DegC
Option board PCB temperature, which is
the thermocouple cold-junction reading.
Network Type
Read Only
566 0 4 Unsigned
16 bits
Selection
Network Interface (if installed):
0 No selection
1 DeviceNet
TM

2 PROFIBUS
3 MODBUS TCP or Ethernet/IP
4 Redundant MODBUS TCP or
Ethernet/IP
Analog Reference #1
Read Only
567 xxx.xx Signed
16 bits
%
Analog input, in percent, as defined by
Analog Reference #1 Selection.
July 2013 Settings
7-29
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Analog Reference #2
Read Only
568 xxx.xx Signed
16 bits
%
Analog input, in percent, as defined by
Analog Reference #2 Selection.
Option Board Type
Read Only
569 xx Unsigned
16 bits
Selection
0 none
1 12301 2000 (THERM HV)
2 12301 2010 (THERM LV)
3 12301 2100 (HV)
4 12301 2110 (LV)
Variant
Read Only
570 xxxx Unsigned
16 bits
Custom configurations of the product
Serial Number
Read Only
572 xxxxxxxxx Unsigned
32 bits
Unique 64-bit identification code,
assigned per unit by Spang. It is
presented as two, 32-bit values.

Serial Number (high)
Read Only
32 bits
Unique 64-bit identification code,
assigned per unit by Spang. It is
presented as two, 32-bit values.
Product Type
Read Only
576 1051 Unsigned
16 bits
1051 Single Phase
MCU Build Number
Read Only
577 xx Unsigned
16 bits
Firmware build reference.
MCU Software Version
Read Only
578 xx.xxx Signed
16 bits
Version
Supervisor firmware, as installed per
unit.
DSP Software Version
Read Only
579 xx.xxx Signed
16 bits
Version
Control firmware, as installed per unit.
Network Software
Version
Read Only
580 xx.xxx Signed
16 bits
Version
Network interface firmware, as installed
per network PCB.
Settings July 2013
7-30
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Display Software
Version
Read Only
581 xx.xxx Signed
16 bits
Version
Graphic Display firmware, as installed
per display assembly.
Analog Output #1
Read Only
582 xxx.xx Signed
16 bits
%
Analog output as defined by Analog
Output #1 Selection in percent.
Analog Output #2
Read Only
583 xxx.xx Signed
16 bits
%
Analog Output #3
Read Only
584 xxx.xx Signed
16 bits
%
Analog Output #4
Read Only
585 xxx.xx Signed
16 bits
%
Analog Output #5
Read Only
586 xxx.xx Signed
16 bits
%
Analog Output #6
Read Only
587 xxx.xx Signed
16 bits
%

DSP Build Number
Read Only
588 xx Unsigned
16 bits
Display Build Number
Read Only
589 xx Unsigned
16 bits
Fault Buffer #1
Read Only
590 xxx Unsigned
32 bits
Fault History entry #1 of a 10-entry
circular buffer. Each entry holds a fault
code (32 bits) and timestamp (32 bits).
Timestamp #1
Read Only
32 bits
July 2013 Settings
7-31
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Fault Buffer #2
Read Only
594 xxx Unsigned
32 bits
Timestamp #2
Read Only
32 bits
Fault Buffer #3
Read Only
598 xxx Unsigned
32 bits
Timestamp #3
Read Only
32 bits
Fault Buffer #4
Read Only
602 xxx Unsigned
32 bits
Timestamp #4
Read Only
32 bits
Fault Buffer #5
Read Only
606 xxx Unsigned
32 bits
Timestamp #5
Read Only
32 bits
Fault Buffer #6
Read Only
610 xxx Unsigned
32 bits
Timestamp #6
Read Only
32 bits
Fault Buffer #7
Read Only
614 xxx Unsigned
32 bits
Settings July 2013
7-32
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Timestamp #7
Read Only
32 bits
Fault Buffer #8
Read Only
618 xxx Unsigned
32 bits
Timestamp #8
Read Only
32 bits
Fault Buffer #9
Read Only
622 xxx Unsigned
32 bits
Timestamp #9
Read Only
32 bits
Fault Buffer #10
Read Only
626 xxx Unsigned
32 bits
Timestamp #10
Read Only
32 bits
Next Fault Store
Location
Read Only
630 xxx Unsigned
16 bits
Next entry to be written to in the circular
Fault History buffer.
Digital Inputs
Read Only
632 0 to
FFFFFFFF
Unsigned
32 bits
Binary
State of the digital interface inputs, as
bits.
Digital Outputs
Read Only
634 0 to FFFF Unsigned
16 bits
Binary
State of the digital interface outputs, as
bits.
July 2013 Settings
7-33
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Network Status
Read Only
16 bits
Binary
Raw network status. Bits 0-2 indicate
network type (ref. Network Type
Selection). Bit 3 indicates the poll
connection state (1=mastered).
Ethernet I/F Subtype
Read Only
636 xx Unsigned
16 bits
Selection
0 None
1 MODBUS/TCP
2 Ethernet/IP
3 PROFINET
Inverted Digital Inputs
Read Only
16 bits
Binary
Inverted state of the digital interface
inputs, as bits.
Poll Read #1 Value
Read Only
666 0 to
FFFFFFFF
Unsigned
32 bits
Binary
By definition, this is the value of the
Status Word. The value is mapped to
the poll block at Input #1.
Poll Read #2 Value
Read Only
668 xxxxxxxx Signed
32 bits
Value of the 1051 setting stated in the
network map as Input #2. The value is
mapped to the poll block at Input #2.
Poll Read #3 Value
Read Only
670 xxxxxxxx Signed
32 bits
Poll Read #4 Value
Read Only
672 xxxxxxxx Signed
32 bits
Poll Read #5 Value
Read Only
674 xxxxxxxx Signed
32 bits
Poll Read #6 Value
Read Only
676 xxxxxxxx Signed
32 bits
Poll Read #7 Value
Read Only
678 xxxxxxxx Signed
32 bits
Settings July 2013
7-34
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Poll Read #8 Value
Read Only
680 xxxxxxxx Signed
32 bits
Poll Read #9 Value
Read Only
682 xxxxxxxx Signed
32 bits
Poll Read #10 Value
Read Only
684 xxxxxxxx Signed
32 bits
Alarm Buffer #1
Read Only
686 xxx Unsigned
32 bits
Alarm History entry #1 of a 10-entry
circular buffer. Each entry holds an
alarm code (32 bits) and timestamp (32
bits).
Timestamp #1
Read Only
32 bits
bits).
Alarm Buffer #2
Read Only
690 xxx Unsigned
32 bits
bits).
Timestamp #2
Read Only
32 bits
bits).
Alarm Buffer #3
Read Only
694 xxx Unsigned
32 bits
bits).
Timestamp #3
Read Only
32 bits
bits).
July 2013 Settings
7-35
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Alarm Buffer #4
Read Only
698 xxx Unsigned
32 bits
bits).
Timestamp #4
Read Only
32 bits
bits).
Alarm Buffer #5
Read Only
702 xxx Unsigned
32 bits
bits).
Timestamp #5
Read Only
32 bits
bits).
Alarm Buffer #6
Read Only
706 xxx Unsigned
32 bits
bits).
Timestamp #6
Read Only
32 bits
bits).
Alarm Buffer #7
Read Only
710 xxx Unsigned
32 bits
bits).
Timestamp #7
Read Only
32 bits
bits).
Settings July 2013
7-36
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Alarm Buffer #8
Read Only
714 xxx Unsigned
32 bits
bits).
Timestamp #8
Read Only
32 bits
bits).
Alarm Buffer #9
Read Only
718 xxx Unsigned
32 bits
bits).
Timestamp #9
Read Only
32 bits
bits).
Alarm Buffer #10
Read Only
722 xxx Unsigned
32 bits
bits).
Timestamp #10
Read Only
32 bits
bits).
Next Alarm Store
Location
Read Only
726 xxx Unsigned
16 bits
Next entry to be written to in the circular
Alarm History buffer.
Unassigned Digital
Outputs
Read Only
16 bits
Binary
Binary representation the assignment
status of Digital Outputs 1-16
Raw Cold Junction
Reading
Read Only
728 xxxxxx.x Unsigned
32 bits
mV
Spang internal use only
July 2013 Settings
7-37
Name
Setting
Number
Range
/Format
Data
Type
Units
Description
Raw Thermocouple
Reading
Read Only
32 bits
mV
Comp Thermocouple
Reading
Read Only
32 bits
mV
AD7792 Setup
Read Only
32 bits
Binary
Integrated Ethernet
Address
Read Only
800 4 octets,
each having
the value 0
255
Unsigned
32 bits

Ethernet address of the units onboard
Ethernet port
Integrated IP Subnet
Mask
Read Only
802 4 octets,
each having
the value 0
255
Unsigned
32 bits

Address Mask for the units onboard
Ethernet port
Integrated Gateway
Read Only
804 4 octets,
each having
the value 0
255
Unsigned
32 bits

Gateway address for the units onboard
Ethernet port

Settings July 2013
7-38
Voltage Output Feedback Range:
The meaning of the selections for the Voltage Output Feedback Range setting are dependent upon the
option board installed, if any.
Selection Part Number Description Low means: High means:
0 na no option board na na
1 123012000
High Voltage,
Thermocouple
up to 240.0V 600.0V max
2 123012010
Low Voltage,
Thermocouple
up to 40.0V 115.0V max
3 123012100 High Voltage up to 240.0V 600.0V max
4 123012110 Low Voltage up to 40.0V 115.0V max

Status Word bit OK to Run
The status bit OK to Run is set when:
There is no fault, and
There is a line sync, and
The unit is enabled

Startup Operation
When Startup Operation (setting 85) is set for Automatic, the 1050 will start (turn on) when:
There is a line sync, and
The unit becomes enabled (Off-to-On transition on Enable input)

OR
The unit is enabled, and
The unit becomes synced to the line

The Stop input will turn off unit output; however, the unit will immediately restart if any of the following is
true (provided there is no fault):
The unit is enabled, there is line sync, and the unit is commanded On (Start input);
There is line sync, and the unit becomes enabled (Off-to-On transition on Enable input);
The unit is enabled, and the unit becomes synced to the line

July 2013 Settings
7-39
Zero Crossover Automatic Power Synchronization
There are well-documented power benefits of Zero Crossover (vs. Phase Angle) power control, including
the elimination of harmonic distortion and near-unity power factor. It is therefore always preferable to use
Zero Crossover when the application permits.
Two of the main application challenges for Zero Crossover control are firing into a transformer primary
and mitigating voltage flicker or sag. A standard analog zero crossover SCR controller cannot fire into
the primary of the transformer. The transformer core will saturate and draw significant current from the
source, causing the fuses to fail or the circuit breaker to open. A phase angle waveform or appropriately
timed zero crossover waveform must be used to set the flux timing in the transformer core to prevent this
from happening.
Spang Power Electronics applies a hybrid phase angle and zero crossover technique.

Figure 7-1 Phase Angle Start Voltage Waveform Figure 7-2 Repetitive Voltage Waveform

The second challenge for Zero Crossover control is to mitigate voltage flicker or sag. Flicker is seen
by the dimming of lights in the plant. When there is a high peak demand (a high current pulse) the source
voltage drops. If the drop is of significant magnitude and of long enough duration, the lights in the plant
flicker (they dim and return to full intensity). This condition may also cause problems with other voltage
sensitive electrical equipment that is connected to the same source.
The Spang 1051 power controller has the capability to automatically distribute firing of individual units
over time so that peak power usage is minimized. This is a continuous adjustment that works to
compensate for output changes in individual units as they operate.
The figures that follow illustrate the worst case power use (no power synchronization) and benefit of
Group Power Synchronization between two power control units or zones. The performance is measured
for two zones, each rated at 100KW and firing at 50% duty cycle, using a 100 cycle time base.

Figure 7-3 Worst case, 100% overlap
In the worst case, there is a complete overlap of the
firing time, i.e. both units are on at the same time.
Note that 200 kW is drawn from the source for 50
cycles while 0 kW is drawn during the subsequent
50 cycles. At 50% duty cycle, each controller is fully
on (full SCR conduction) for 50 cycles and then off
for 50 cycles.

0
50
100
150
200
250
1 10 19 28 37 46 55 64 73 82 91 100
Cycle Number
k
W
Settings July 2013
7-40

Figure 7-4 50% Overlap
Partial synchronization results in 50% overlap. The
peak power continues to be 200 KW but with shorter
duration.

Figure 7-5 Improved Synchronization, 10%
Overlap

Figure 7-6 Synchronized, 0% Overlap
The optimum condition results in 0% overlap and full
synchronization. With full synchronization, the peak
power demand is reduced from 200 KW to 100 KW.

Synchronization of the zero crossover firing time reduces voltage flicker and associated problems with
voltage sensitive electrical equipment.
The solution dynamically changes individual unit firing time during operation to minimize voltage flicker.

0
50
100
150
200
250
1 10 19 28 37 46 55 64 73 82 91 100
Cycle Number
k
W
0
50
100
150
200
250
1 10 19 28 37 46 55 64 73 82 91 100
Cycle Number
k
W
0
50
100
150
200
250
1 10 19 28 37 46 55 64 73 82 91 100
Cycle Number
k
W
July 2013 Settings
7-41
The following figures illustrate a 12 zone and a 39 zone system with active power synchronization. Each
block of a particular color represents a single zones power contribution. Firing times and overlap are
minimized. Both systems are fully synchronized.

When a given unit sees that it has collided with another, it makes a timing correction to minimize
the peak demand. The process continues and makes corrections automatically over time. The following
figure illustrates the synchronization of a 39 zone system with all zones forced to initially fire
simultaneously. Here, synchronization is achieved in less than 40 seconds.

Figure 7-9 39 Zone Synchronization Performance

0
500
1000
1500
2000
2500
1 241 481 721 961 1201 1441 1681 1921 2161
Cycles (40 Seconds Total)
P
o
w
e
r

(
k
W
)
0
100
200
300
400
500
600
1 10 19 28 37 46 55 64 73 82 91 100
Cycle Number
k
W
0
100
200
300
400
500
600
1 10 19 28 37 46 55 64 73 82 91 100
Cycle Number
k
W
Figure 7-7 12 Zone Example Figure 7-8 39 Zone Example
All units firing at
the same time
Synchronization
achieved in
approximately 32
seconds
Settings July 2013
7-42
Analog Configuration
To configure Automatic Group Power Synchronization, a physical connection is wired between SCR
controllers; the connection is a two-wire pair which carries an analog signal. Each unit is both
transmitting and receiving information on a continuous basis. Each SCR controller tracks total
available power from all units, total actual power each cycle, and its own power contribution. At
the end of the units power cycle (using a 100 cycle time base), it will analyze the data and automatically
shift its pulse timing to minimize total peak power. The process is automatic and continuous, looking at
the data, reviewing, and correcting as necessary at the end of every power cycle.
One Analog Output and one Analog Reference (per unit) are used to communicate power usage between
1051 units. Each unit uses its assigned Analog Output to represent its own instantaneous usage. The
output is configured for 0-20mA; the maximum current output, 20 mA, represents the total group power
(all units are on at the same instant). The Sync Group Power Rating is the sum total full power output
(by rating) capability for all the units tied together by the analog current loop. It is imperative that the
Sync Group Power Rating is calculated accurately and set for each unit in the group.
The assigned Analog Input (reference) provides each unit with a sense of the instantaneous total group
power. Using the Sync Group Power Rating, this measurement is scaled as a power value represented
by the setting Group Power Reading.
It is important to note that if the individual 1050 unit is controlled locally via Analog reference, Sync Group
Power operation will require the option board (123012xxx) to provide an additional analog input.

Analog setup for
Automatic Power Synchronization
July 2013 Settings
7-43
1 2 3 4
ON (closed)
SW1-1 = Open (OFF) Voltage Reference
SW1-2 = Closed (ON) Single Ended (ie. ground)
1051 Dip Switch Settings
Note: All PCUs within a
common synchronization ring
must share a common ground
point (ie. electrically maintaining
the same ground potential).
Burden Resistor
249, 0.25 Watt (min), 1%
Note: Should maintain a stable resistance
value with fluctuations in temperature.

Analog INPUT (typ.) Ain1 or Ain2
( SW1 ) Control or
( SW1 ) Option Board (if applicable)
Control board
Aout1 (SW1-3) = Open (OFF) Current Source
Option board

Analog OUTPUT (typ.) Aout1 thru Aout6
( SW1 ) Control Board or
( SW2 ) Option Board (if applicable)
1 2 3 4
ON (closed)
Control Brd (Ain1)
1 2
ON (closed)
Option Brd (Ain2)
1 2 3 4
ON (closed)
Option Brd Control Brd
1051 Unit 1
Ain Ref (+)
Ain Ref ()

Aout (+)
Aout ()

1051 Unit 2
Ain Ref (+)
Ain Ref ()

Aout (+)
Aout ()

1051 Unit n
Ain Ref (+)
Ain Ref ()

Aout (+)
Aout ()

Figure 7-10 Analog Connections, Group Power Synchronization
Settings July 2013
7-44
Group Power Calculation
The Sync Group Power Rating is the sum of the rated power of each unit, unless additional
considerations such as multi-tap transformer source power cause the ratings to be much higher than
actual power usage.
All units in a group must have the same Sync Group Power Rating. The power usage reported by each
unit is a ratio of the units individual power to the total group power.

As noted previously, once Automatic Power Synchronization becomes active, the system configuration
will achieve optimal power-sharing operation in a timely manner, depending on system topology and
characteristics.
Rating setup for
July 2013 Settings
7-45

Settings July 2013
7-46
Scaling of Power Data
The raw values for power calculations are kept internally in Watts. The data is scaled for display and
presented as Kilowatts in the Spang LDC and the Configuration Tool Application.
For network communication, power data is read and written as Watts.
Timed Digital Input Selections
There are four timed options for digital input assignments:
Timed Fault when input is closed;
Timed Fault when input is open;
Timed Alarm when input is closed;
Timed Alarm when input is open

The alarm or fault will be latched after a (fixed) time delay of approximately 5 seconds.
Alarm Bits and the Alarm Filter Setting
The Alarm Status Bits settings define a bit for each possible alarm. If the alarm is active, its
corresponding bit in the Alarm Status Bits setting will be active.
The complementary Alarm Filter settings are a user-configurable mask applied to the Alarm Bits setting.
The mask defines which alarms, if any, will trigger the Filtered Alarm Bit in the Status Word. The user
can monitor the Filtered Alarm Bit to react to specific operating and status conditions.

Alarm Filtering Example
The following example illustrates the use of the Alarm Filter setting to trigger the Filtered Alarm Bit in
the Status Word.
Referring to the Alarm Status Bits setting in the settings table, note the bit defined for the Input #1
Alarm is bit 4. The corresponding mask bit is bit 4 of the Alarm Filter setting; the decimal value of the
mask is 2
4
or 16.

July 2013 Settings
7-47

Digital Inputs are
configured for Alarm
when Closed.
Set the Alarm Filter =
16 decimal, the mask
for Digital Input #1.
Settings July 2013
7-48

Note the Digital
Inputs and Alarm
Status.
When Digital Input #1
opens, the Digital
Input status and
Alarm Status change.
July 2013 Settings
7-49
It is possible to mask multiple alarms. The bit defined in the Alarm Status Bits setting for the
Reference #1 Wirebreak alarm is bit 25. The corresponding mask bit is bit 25 of the Alarm Filter
setting, with a decimal value of 2
25
or 33,554,432.
To trigger the Filtered Alarm Bit in the Status Word for either of the above-referenced alarms, the
Alarm Filter setting must have a value of 16 + 33,554,432 = 33,554,448.

The highest-priority alarm is recorded in the Alarm Code setting.

It is possible to mask
multiple alarms. Any
of the masked bits will
trigger the Alarm
Status Bit.
Settings July 2013
7-50

8-1
Chapter 8
Faults, Alarms, and Troubleshooting
DANGER

of life.

DANGER

The user is responsible for conforming to all applicable local, national, and international
particular importance. Failure to observe this precaution could result in severe bodily
injury or loss of life.

DANGER


DANGER

Power must be applied to the 1051 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.

Troubleshooting July 2013
8-2

Figure 8-1 Control Board LEDs
LED Color Status Description
Power Green On, solid Control power is present
Enable Green On, solid Unit output is enabled
Run Green On, solid Unit Output is On
Alarm Amber Off No alarm
Alarm Amber On, solid Unit is alarming
Fault Red Off No fault
Fault Red On, solid Unit is faulted
HB1 Green On, flashing Normal operation = 0.5 sec. flash rate
HB2 Green On, flashing Normal operation = 0.5 sec. flash rate

Under normal operation, the Power and Enable LEDs will be on steady. HB1 and HB2 will flash at a 0.5
second flash rate. The Run LED will be on steady if the unit output is on. If no alarm or fault is present,
the user will see only green light.

July 2013 Troubleshooting
8-3
Fault and Alarm Codes
Table 8-1 Fault and Alarm Codes (1051 Single Phase)
Fault Code Description Alarm Code Description
0 No Fault 100 Line Sync Alarm
1 Configuration Fault 101 Frequency Alarm
2 DSP Fault 102 Voltage Input Low
3 Voltage Input High 103 Voltage Output Limit
4 Voltage Input Low 104 Current Output Limit
5 Current Output High 105 Power Output Limit
6 Current Input High 106 Maximum Voltage Output
7 SCR High Temperature 107 Retrying on Output Overcurrent
8 Network Loss 108 Output Current High
9
Configuration Requires Option
Board
110 Real Time Clock Not Set
10 Process Temperature High 111 Current Input Limit
11 Process Timed Temp High 112 Network Loss
12 Thermocouple Wire Break 113 Retrying on Input Overcurrent
13 Firmware Mismatch 114 Process Temperature Limit
14 Input #0 Fault 115 Process Temperature High
15 Input #1 Fault 116 Process Temperature Low
16 Input #2 Fault 117 Thermocouple Wire Break
17 Input #3 Fault 118 Reference #1 Wire Break
18 SCR Shorted 119 Reference #2 Wire Break
120 Input #0 Alarm
121 Input #1 Alarm
122 Input #2 Alarm
123 Input #3 Alarm
124 Heatsink Temperature High
125 Heatsink Temperature Sensor
126 Tap Change Alarm

Fault conditions are prioritized and evaluated from low to high; the lower the fault code, the higher its
priority. If a fault occurs, the 1050 output is shut down and the fault is latched (the fault must be reset).
The fault is accessible through the Fault Code setting. The Fault Code is shown on the Local Display,
and can be read by the Configuration Tool or across the network interface.
Alarm conditions are considered warnings and do not stop the 1050. The existing alarm code is
accessible through the Alarm Code setting. The Alarm Code is shown on the Local Display, and can be
read by the Configuration Tool or across the network interface.
A fault will always override an alarm and stop the 1050.

8-4
Fault Reset
If the fault condition is resolved, the fault latch can be cleared (reset) by one of several methods.
From the Fault Display mode on the Local Display, press [RES].
From the Configuration Tool application, click the [Fault Reset] button.
Under external serial or network control, directly address the Fault Reset Bit (bit 1) of the Control
Word. The bit must be momentarily set to enable a fault reset.
One of the digital inputs can be configured as a fault reset.

Fault History
The last ten faults are stored in Fault Buffers #1 - #10. The buffers are assigned setting numbers and
can be read. Each buffer includes the Fault Code and a time stamp based on the 1050 unit time. Only
faults that occur when the unit output is on are buffered. The fault buffers are connected in a circular
fashion.
The Fault History can be cleared by momentarily setting the Clear Fault History Bit (bit 3) of the
Control Word.

Alarm History
The last ten alarms are stored in Alarm Buffers #1 - #10 and are assigned setting numbers. Each buffer
includes the Alarm Code and a time stamp from the start of the alarm condition. The alarm buffers are
connected in a circular fashion.
The Alarm History can be cleared by momentarily setting the Clear Alarm History Bit (bit 4) of the
Control Word.

8-5
Troubleshooting Guide
DANGER

of life.

DANGER


DANGER


DANGER

Power must be applied to the 1050 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.
8-6
Table 8-2 Troubleshooting Guide
Condition Probable Cause Corrective Action
Power supply LED off No Control Power Insure the 1051 has separate control power
HB1 LED off Unit is in Flash Program
mode
Check flash jumper JP1. If Flash
Programming is complete, remove jumper
and cycle power to main control PCB
DSP on main control PCB
failed
Consult factory
HB1 LED flashing
slowly (2.5 sec rate)
Unit is in Flash Program
mode
Check flash jumper JP1. If Flash
Programming is complete, remove jumper
and cycle power to main control PCB
HB1 LED flashing
rapidly
DSP sees an MCU
communications fault.
Consult factory
HB2 LED off Unit is held in reset Consult factory
Display off
connection open or
intermittent
Check Local Digital Control power
connection
Display shows no data
Ethernet cable missing or
unplugged
Check physical Ethernet cabling
IP address(es) not configured Check LDC IP address settings
Cannot establish
comm between Config
Tool and Control

Ethernet cable missing or
unplugged
Check physical Ethernet cabling
SD card missing or not
properly seated
Check control SD card installation;
cycle power to the unit
IP address(es) not configured Check IP address settings
1051 will not turn on in
Local Analog mode
Enable input not present Check the Enable input.
Remote input present Check the Remote/Local input.
Analog mode not selected Select Analog mode using the Local Digital
Control or Configuration Tool. Check the
Analog status.
8-7
Analog setpoint set to zero Verify voltage at Analog Setpoint input
Analog setpoint calibration
incorrect
Verify Analog setpoint calibration
Run LED is off: No main
power
Check incoming power supply and
connections
Run LED is off: Incoming
main power is not within
specification
Minimum 10% of rated voltage must be
applied, at frequency between 45-65Hz
Local Digital mode
Enable not present Check the Enable input.
Remote input present Check the Remote/Local input.
Digital mode not selected Select Digital mode using the Local Digital
Control or Configuration Tool. Check the
Digital status.
Output On not selected Toggle the On/Off pushbutton (LCD or
Configuration Tool) and check the Output
On status.
Run LED is on: Control
setpoint may be set to zero
Increase the setpoint
Run LED is on: Limiting
condition may be present
Check current, voltage and power limits and
setpoints
Check PID gains
Run LED is off: No main
power
Check incoming power supply and
connections
Run LED is off: Incoming
main power is not within
specification
Minimum 10% of rated voltage must be
applied, at frequency between 45-65Hz
Check Voltage calibration

8-8
Remote mode
Enable not present Check the Enable input.
Remote input not present Check the Remote/Local input.
1051 is not mastered. Check the network connection and masters
configuration.
On/Off bit not set to one The Control Word is continuously written
from the master to the 1051 and must be
MAINTAINED.
Setpoint set at zero The setpoint and limit values in the network
poll block are continuously written from the
master to the 1051 and must be
MAINTAINED.

1051 cannot provide
full power to the load
Calibration incorrect Check calibration
Power is being limited by one
of the control loops
Verify setpoints and limits for the control
loops
1051 is full on and cannot
provide any more power
Duty Cycle is at 100.0%.
Review the load to verify that 100.0%
voltage will allow 100.0% power.
Verify input voltage level
Output wiring intermittent or
disconnected
Check the output wiring
Nuisance Input Fuse
blowing
Improper fuse rating Consult the factory for proper fuse rating
Fuse improperly tightened Tighten the fuses
Environment temperature too
high
Lower environment temperature
F 01 Configuration
Fault

Failed FRAM memory Replace main control PCB
8-9
F 02 DSP Fault Main control PCB out-of-sync Cycle power
Failed DSP Replace main control PCB
F 03 Voltage Input
High
Incorrect Voltage Input
Rating (L-L)
Check the Voltage Input Rating
Incorrect Voltage Input High
Fault (L-L)
Check Voltage Input High Fault setting
Incoming voltage out of
tolerance
Correct incoming voltage level
Incorrect Input Voltage
Feedback Range
Check Input Voltage Feedback Range
F 04 Voltage Input
Low
Rating (L-L)
Incorrect Voltage Input Low
Fault/Alarm (L-N)
Check Voltage Input Low Fault/Alarm
setting
Feedback Range
tolerance
Blown input fuse Replace input fuse
F 05 Current Output
High

Instantaneous current
exceeds the Current High
Fault and retries (if any) have
been attempted
Check load integrity
Examine SCRs
Check connections
Adjust setpoint (limits)
8-10
F 06 Current Input
High

instantaneous current
Fault and retries (if any) have
been attempted
Examine SCRs
Check connections
F 07 SCR High
Temperature

high
Airflow to heat sink blocked Increase airflow
Bad temperature sensor Consult factory
F 08 Network Loss Network interface board not
installed
Network interface board not
physically connected to the
network
No network power
Check network interface board installation
Check network connection
Verify network power
Change Network Loss Option to allow
device operation
F 09 Configuration
Requires Option Board
Feedback Source is set to
Remote feedback
Check Feedback Source setting
F 10 Process
Temperature High
The process temperature has
exceeded the high limit
Check controller output is not shorted on.
F 11 Process Timed
Temperature High
exceeded the high limit for an
extended time
F 12 Thermocouple
Wire Break
The process temperature
thermocouple is not making
connection to the controller
input
Repair the thermocouple connection or
broken wire
F 13 Firmware
Mismatch
The product type and/or
variant code of the control
and peripheral processors do
not match.

Check processor diagnostics using the
config tool; consult factory for possible
firmware update
8-11
Fault Conditions 14 17 are user-configurable.
F 14 F 17
Digital Input Fault
(Digital Inputs 0-3)
Digital Input Selection vs. Digital Input status.

F 18 SCR Shorted Current flow has been
detected when SCRs are not
firing
Check for shorted SCR or mis-connected
current sense
Alarms
A 100 Line Sync Unit is out-of-sync with
incoming AC line
Check incoming line and connections
A 101 Frequency
Alarm
Frequency Rating setting
incorrect
Check Frequency Rating selection
Incoming frequency out of
tolerance (+/- 2%)
Correct incoming frequency
A 102 Voltage Input
Low
Rating (L-L)
Incorrect Voltage Input Low
Fault/Alarm (L-N)
Check Voltage Input Low Fault/Alarm
setting
tolerance
Blown input fuse Replace input fuse
Feedback Range
A 103 Voltage Output
Limit
Voltage Output Limit setting
incorrect
Check Voltage Output Limit setting
PID gains are set too low

Check PID gains
8-12
A 104 Current Output
Limit
Current Output Limit setting
incorrect
Check Current Output Limit setting
PID gains are set too low Check PID gains
A 105 Power Output
Limit
Incorrect Voltage Rating Check Voltage Rating
Incorrect Current Rating Check Current Rating
Incorrect Power Setpoint
Limit
Check Power Setpoint Limit
PID gains are set too low Check PID gains
A 106 Maximum
Voltage Output
Duty Cycle has reached
100%
Lower the control setpoint
A 107 Retrying on
Output Overcurrent
There has been a current trip
and retries are occurring
Examine SCRs
Check connections
Check load for possible short condition
A 108 Current Output
High

Instantaneous current
Alarm
Examine SCRs
Check connections
A 110 Real Time
Clock Not Set
Use Configuration application to set the
real-time clock
A 111 Current Input
Limit
Current Input Limit setting
incorrect
Check Current Input Limit setting
PID gains are set too low

Check PID gains
8-13
A 112 Network Loss Network interface board not
installed
Network interface board not
physically connected to the
network
No network power
Check network interface board installation
Check network connection
Verify network power
Change Network Loss Option to allow
device operation
A 113 Retrying on
Input Overcurrent
There has been a current trip
and retries are occurring
Examine SCRs
Check connections
A 114 Process
Temperature Limit
Alarm
exceeded the high limit
A 115 Process
Temperature High
exceeded the high alarm
A 116 Process
Temperature Low
dropped below the low alarm
Check controller output is powering the load
and the source voltage is connected to the
controller input.
A 117 Thermocouple
Wire Break
The process temperature
thermocouple is not making
connection to the controller
input
Repair the thermocouple connection or
broken wire
A 118 Reference #1
Wire Break
The reference wire is not
making connection to the
controller input
Repair the connection or broken wire
A 119 Reference #2
Wire Break
The reference wire is not
making connection to the
controller input
Repair the connection or broken wire
Alarms 120 123 are user-configurable.
A 120 A 123
Digital Input Alarm
(Digital Inputs 0-3)
Digital Input Selection vs. Digital Input status.

8-14
A 124 Heatsink
Temperature High
high
Airflow to heat sink blocked Increase airflow
Bad temperature sensor Consult factory
A 125 Heatsink
Temperature Sensor
No feedback from
temperature sensor
Consult factory
A 126 Tap Change
Alarm
The unit has phased back to
a controllable level (indicating
poor power factor)
Change the transformer to a lower tap; or
change the Tap Change Alarm level

8-15
Fuse Replacement
DANGER

of life.
DANGER

DANGER


Figure 8-2 200A and 400A Fuses

8-16
To replace a line fuse:

1. Disconnect the main power source and lockout/tagout the source. Verify with meter that the
voltage is de-energized.
2. Remove the blue covers from the power controller.
3. Remove the two top mounting screws for the control circuit board. Tilt the control board down to
reveal the fuses.
4. Using a digital volt meter, test each fuse with the ohms scale. A good fuse should be a low
resistance of less than 1.0 ohms.
5. Remove opened fuse(s) by loosening the two bolts or nuts attaching the fuse to the bus bars.
6. Install the new fuse(s) and tighten the two bolts or nuts on each to 240 Lbf-Inch [13 N-m].
7. Replace the control circuit board and tighten its mounting screws.
8. Replace the blue covers.
9. Remove the lockout/tagout label and re-energize the controller.

A-1
Appendix A
Sample Web-Server Setup
Please note: The example that follows illustrates a locally-hosted, off-line Spang Configuration
Tool App. The example does not indicate necessary or mandatory steps involving normal
communication between the host computer and the 1051 Power Control unit. Refer to the
Configuration and Monitoring section elsewhere in this manual for details regarding normal
communication between the host computer and the 1051 Power Control unit.
The 1051 Power Control unit has a built in web server to serve the Spang Configuration Tool App. The
Configuration Tool can also be hosted offline; that is, independent from the 1051 Power Control unit, to
create and edit configuration files. The Firefox browser (version 19.02 or newer) can open the
Configuration Tool Application directly from the PC without a web-server. Other browsers may
have the same capability.
If desired, an independent, freeware web server can be used to serve the Configuration Tool.
The following example illustrates the use of the freeware web server HFS to host the Spang
Configuration Tool locally. HFS is just one example of a locally hosted web server. Other web servers
may be used instead.
Step 1-
Spang supplies a media card (MicroFlash or CD ROM) with the Flash files needed for the Spang
Configuration Tool App. Open the media and copy the contents of the micro SD card to a local folder on
the host computer. The contents of the folder are similar to those below. Note the location of the local
folder.

Web-Server Setup July 2013
A-2
Step 2-
Run the desired web browser on the host computer. Do a web search for HFS web server. Download
the HFS installation file to the host computer.
Run the HFS installation file. If asked to add the shell, click [No].

When the HFS program opens, select the Menu and task Add folder from disk ..

Select the Flash folder just created and click OK.
July 2013 Spang 1051

A-3

In the pop-up window, select Real folder.

To start communications click on Open in browser
A-4

In the browser, double click on the ConfigTool.HTML file.

The browser will display the 1050 web page.
July 2013 Spang 1051

A-5

To reiterate, this example illustrates a locally-hosted, Spang Configuration Tool App.

The example does not indicate necessary or mandatory steps involving normal communication
between the host computer and the 1051 Power Control unit. Refer to the Configuration and
Monitoring section elsewhere in this manual for details regarding normal communication
between the host computer and the 1051 Power Control unit.

A-6

B-1
Appendix B
Mechanical Dimensions

Mechanical Dimensions July 2013
B-2

Physical Dimensions: 15 - 200 Amp

Note: All dimensions to (1) mm.
MW
W
Z
MH H
D
9.46
[240]
LOCAL DISPLAY
(OPTIONAL)
X1
L1
July 2013 Mechanical Dimensions
B-3

Physical Dimensions: 300 - 400 Amp

Mechanical Dimensions July 2013
B-4

Physical Dimensions: 600 Amp


C-1
Appendix C
Electrical Characteristics
Electrical Characteristics July 2013
C-2
July 2013 Electrical Characteristics
C-3

Figure C-1 1051 Electrical Schematic

C-4

C-5

Figure C-2 1051, 600 Amp Schematic
C-6
Control Power VA Requirements
The following table describes VA requirements for Spang 1050 Series products by frame size and current
rating.
Table C-1 Control Power VA Requirements
1051 15, 25, 50A 100A 200A 300A, 400A, 600A
Power Supply 15 15 15 15
Fans (Heatsink) na 11 11 25
Fans (control) 0 0 9 9
Total Power (VA) 50 50 50 75

1052 15, 25, 50A 100A 200A 300A, 400A, 600A
Fans (Heatsink) 0 22 22 50
Total Power (VA) 50 50 75 100

1053 15, 25, 50A 100A 200A 300A, 400A, 600A
Fans (Heatsink) 0 66 66 150
Total Power (VA) 50 100 150 200

C-7
Spang 1050 Series, 1051 Watt Losses
The approximate values assume a fixed value for general control losses within a frame size. The
indicated watts loss varies by the calculated SCR & I2T fuse losses at a given amperage.

Table C-2 1051 Watt Losses

AMPS WATTS AMPS WATTS AMPS WATTS AMPS WATTS AMPS WATTS
2 13 3 19 5 26 10 36 20 56
3 14 5 21 10 30 20 44 40 72
5 15 8 23 15 34 30 53 60 90
6 17 10 25 20 38 40 62 80 108
8 18 13 27 25 42 50 72 100 126
9 19 15 29 30 47 60 83 120 147
11 20 18 31 35 52 70 94 140 169
12 21 20 33 40 58 80 106 160 195
14 23 23 35 45 64 90 121 180 219
15 24 25 37 50 70 100 135 200 245

AMPS WATTS AMPS WATTS AMPS WATTS AMPS WATTS
30 69 40 86 60 121 100 186
60 93 80 120 120 168 200 273
90 117 120 154 180 217 300 363
120 143 160 190 240 267 400 458
150 170 200 226 300 319 500 556
180 199 240 265 360 375 600 665
210 230 280 305 420 432 700 777
240 264 320 352 480 494 800 901
270 299 360 396 540 558 900 1042
300 336 400 441 600 622 1000 1176

C-8
Agency Approvals
Table C-3 Agency Approvals
1051/52/53 Labeling Package SCCR Rating
Ie UL CE RoHS Type Rating
Type Protection**
15 Y Y, IP20 Y Touch-proof 100 kA 2
600
*
Y, IP20 Y Touch-proof 100 kA 1
1000 * Y, IP00 Y Panel-mount 100 kA 1

* In process
**
Type 1 Protection: Under short-circuit conditions, the contactor or starter shall cause no danger to
persons or installation and may not be suitable for further service without repair and replacement of parts.
Type 2 Protection: Under short-circuit conditions, the contactor or starter shall cause no danger to
persons or installation and shall be suitable for further use.

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July 2013

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