Frequently Asked Questions
Theory of Operation
An SCR power controller is a silicon controlled rectifier, a controllable diode with support electronics, heat management, and safety packaging. SCRs can be used in a variety of applications to control the power, current and voltage to your load. See our list of applications: https://ccipower.com/industries. Please feel free to contact us if you do not see your application on this list.
Phase Angle controllers work like a light dimmer. The load voltage is varied by varying the time within each electrical half-cycle during which voltage is applied to the load.
Zero Cross is analogous to a very fast contactor that “makes” only at the beginning of each electrical half-cycle and always “breaks” at the end of the electrical half-cycle.
Phase Angle can be used to control all loads. Phase Angle must be used to power transformer coupled loads and fast heating loads like lamps. In addition to generating substantially less harmonics than Phase Angle controllers, Zero Cross is lower in price and slightly more reliable.
SCR controllers offer infinite resolution and features such as voltage compensation, current limiting, and Overcurrent Trip. SCR controllers are often less expensive and don’t have inherent wear-out modes
Approximately 1.2 watts per amp switched per power line controlled by an SCR.
SCR controllers generally operate on all of the commonly available command signals of the various temperature controllers and PLC outputs, including:
- Analog signals – 4-20mA, 0-5Vdc, 0-10Vdc
- Potentiometer
- On/off 3-32Vdc, 0-24Vdc, 0-120 VAC or 0-240 VAC
Other command signals can be ordered to match older control signals (including 2-12 mA, 12-20 mA, 1.2-6 Vdc).
The following fieldbus interfaces are also available on Control Concepts digital controllers:
- DeviceNet (ODVA-certified DeviceNet)
- Modbus TCP RTU (RS-485)
- Modbus TCP (Ethernet)
- PROFINET (Ethernet)
- EtherNet/IP (Ethernet)
Check product specifications to ensure your controller meets your requirements.
Yes, they do generate harmonics on power lines.
Zero Cross controllers generate most harmonics below 50/60 cycles.
Phase Angle controllers generate harmonics above 50/60 cycles. For single phase controllers, the largest distortions occur at 3rd, 5th, and 7th harmonics. For three phase controllers, all multiples of the 3rd harmonic are not created.
Harmonics may cause overheating of inductive equipment, such as transformers, motors, etc. However, actual occurrences of this issue are essentially non-existent.
About Our Power Controllers
Please visit our product selector page or support to contact our team of experts. For fastest service, please have the following information available:
- Voltage
- Single or three phase
- Load current and type
- Command signal
- Other features
For more information, please visit our How to Order page.
Most controllers manufactured by Control Concepts have been tested by Underwriters Labs to UL and CSA standards and carry the UL and CUL marking. Some controllers have received CE certification from TUV America. Check product specifications or reach out for more information.
Please refer to pages 6 & 7 of the MicroFUSION datasheet for a table explaining which features are available. We recommend using the HX model if digital communications are needed.
This setting is defaulted to 4-20mA, but you can change to another signal such as 0-5Vdc or 0-10Vdc with Control Panel software. There is a settings change option in the ‘Quick Setup’ or the Analog Inputs tab of Control Panel. The scaling is also adjustable in the Analog Inputs tab. Please refer to the manuals or reach out with questions.
This alarm indicates the SCR cannot achieve its commanded output. For example, the full scale voltage may be set to 480 VAC, but the line supply is only 460 VAC. If the SCR is commanded to go to 100% output, it physically cannot achieve 480 VAC on a 460 VAC supply; the Low Output Alarm will activate. Once the SCR is able to reach its setpoint, the alarm will go away. This alarm can be disabled, or the full scale settings can be adjusted to eliminate this alarm’s cause.
About Control Concepts
Control Concepts is located at 8077 Century Blvd, Chanhassen, MN, 55317, US. All our products are designed, tested, and shipped from this US based location.
MicroFUSION, ATOM, FUSION and other standard products ship within 1-2 weeks after receipt of order. If large quantities are needed, please contact us for lead time.
Control Concepts supports a large inventory of parts. Most orders are built to order and ship within 1-2 weeks. If you are in an emergency situation, overnight shipments are available same or next day.
Normal business hours are 8:00am – 5:00pm CT
Control Concepts offers a variety of ways to contact us.
- Chat on our website
- By phone: 952-474-6200
- By email: sales@ccipower.com
Quotes and Orders
You can email your request to sales@ccipower.com or find a representative in your area. For more information, please visit our How to Order page.
Please send your PO to sales@ccipower.com.
Once an order ships, the tracking number is automatically sent via email to the buyer listed on the purchase order (PO). For orders placed through the website, the tracking number and link can be found on your order page, and will also be emailed to the email address on the account.
Please submit your request here or contact us for additional support.
Yes, we stock a variety of touch-safe branch rated fuses. We recommend you fuse your load at 125% of either the full load current or the SCR’s frame rating.
Fuses also help certify our products as UL, CE & 100KA SCCR rated.Â
Product Documentation and Software
Please visit the bottom section of the product page’s specifications section. Legacy manuals and CAD files can be found here.
Firmware is not available to download from our website. Please contact our Sales Application Engineers to determine if a firmware upgrade is right for you.
Download our free Control Panel Software here.
Yes. After a 10 day trial, you will need to register with basic user information. Registration and use of the software is free. You can register for a code here after creating a free Control Concepts user account.
Your control panel code can be found here. It was also emailed to the email address for the account; please check your junk email folder. If you still need assistance, please contact us.
Some Micro USB cables lack high enough quality to transmit data. Try a different USB cable; USB 2.0 is known to be successful in connecting.
 The digital interface files can be downloaded on each product page, or the Legacy Manuals and CAD Blocks page for legacy products.
Fusing CAD files can be downloaded directly from the Littelfuse website.
Wiring and Installation
As SCR controllers aren’t safety disconnects, some sort of safety disconnect is usually required. Please consult your local electrical codes.
Yes, +24 Vdc is required for all MicroFUSION units. +24 Vdc is connected on Pins 1(-) & 2(+). Please make sure the +24 Vdc LED is green. If it’s red, the polarity is reversed. See page 9 of the datasheet for power consumption.
Control Concepts recommends protecting the SCR with a class T fuse, which is an excellent compromise between protection and premature fuse failure.
Generally yes, provided the total load current is not more than the SCR controller is rated to handle.
Size the fuses to be 25% over the full load current. For a 30A single phase load, fuse the SCR controller at 40 Amps with a very fast fuse (Type T or faster).
Derating is necessary with most manufacturers’ controllers, starting at as little as 25 degrees C (room temperature).
However, our controllers are rated at 55 degrees C (130 degrees F), meaning that derating is not usually required.
Consider the cost savings. With many controllers, in order to control 120A at 55 degree C, 200 A controllers are necessary due to their derating curves. With our controllers, you can order a 120A controller and actually control 120 amps without overheating or failing prematurely.