Ametek ZF2 Series Bedienungs- und Wartungshandbuch

SCR POWER CONTROLLER

Instruction, Operation and

Maintenance Manual

Number: 9100039

Revision 2

530 Lakeview Plaza Blvd, Ste C

Worthington, Ohio, USA 43085

Toll Free: 1-888-PWR-CNTL (797-2685)

Phone: 614-308-5500

Fax: 614-308-5506

Web: www.hdrpower.com

ZF2/ZF3 SSR Series

15-70 Amperes

Two/Three-phase

Zero-fired

This manual applies to all Model ZF2 and ZF3 SSR Power Controls. Former ZF2/ZF3 manual – 9100028 has

been replaced with this manual.

For the support representative nearest you, please call Ametek HDR Power Systems main office at (614)-308-

5500.

Revision 1 September 2014 Initial Release

Revision 2 July 2015 Revised Address

2015 by Ametek HDR Power Systems. No portion of this document may be reproduced either mechanically or electronically without the

prior consent of Ametek HDR Power Systems.

ZF2/ZF3 SSR Power Controller Table of Contents

Rev 2 Ametek HDR Power Systems i

TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS .............................................................................................................1

CHAPTER 1 - DESCRIPTION..............................................................................................................................3

1.1General Description 3

1.2Application 3

1.3Specification 3

1.4Option NO/NC (Thermostat) 3

1.5Option FK (Fuse Kit) 3

1.6Option TX (24 Vac Transformer) 3

1.7Option UB (Load Unbalance Alarm) 4

1.8Option SF (SCR Failure Alarm) 4

CHAPTER 2 - INSTALLATION............................................................................................................................5

2.1Mounting the ZF2/ZF3 5

2.2Load Wiring 5

2.3Line Wiring 5

2.4Wiring Input Fuse 6

2.5Command Signal Input 6

2.6Heatsink Thermostat Contacts 6

CHAPTER 3 - OPERATION.................................................................................................................................7

3.1General 7

3.2Command Indicator 7

3.3Command Input Control 7

CHAPTER 4 – TROUBLESHOOTING.................................................................................................................9

4.1Customer-Service Program 9

4.2Troubleshooting Typical Symptoms 9

4.3Static Precautions when Servicing 9

4.4Environmental Problems 10

4.5Input Power and Load Connections 10

4.6Correcting Troubles in the ZF2/ZF3 Itself 11

CHAPTER 5 - SERVICE.....................................................................................................................................13

5.1Communication Procedures 13

5.2Spare Parts Orders – Routine or Emergency 13

5.3Spare Parts List 14

5.4Drawing List 15

CHAPTER 6 – WARRANTY POLICY................................................................................................................17

6.1Warranty 17

6.2In-house Repair Services 17

APPENDIX..........................................................................................................................................................18

Appendix A – ZF2 System Schematic (-C models only) 18

Appendix B – ZF2 System Schematic 19

Appendix C – ZF3 System Schematic 20

Appendix D – ZF2 15-40 A Outline 21

Appendix E – ZF2 70 A Outline 22

Appendix F – ZF3 15-40 A Outline 23

Appendix G – ZF3 70 A Outline 24

Appendix H – Option Transformer Outline 25

Appendix I – Option FK Mounting 25

Table of Contents ZF2/ZF3 SSR Power Controller

ii Ametek HDR Power Systems Rev 2

Appendix J – Declaration of Conformity 26

TABLES

Table 1.1 ZF2/ZF3 Model Number Breakdown ................................................................................................ 3

Table 1.2 General Specifications of ZF2/ZF3 SSR Models............................................................................. 4

Table 2.1 Control Transformer Voltage Wiring............................................................................................... 5

Table 4.1 Troubleshooting Chart (Symptoms and Solutions)..................................................................... 11

Table 5.1 ZF2 SSR Spare Parts List ............................................................................................................... 14

Table 5.2 ZF3 SSR Spare Parts List ............................................................................................................... 14

Table 5.3 ZF2/ZF3 SSR Drawing List.............................................................................................................. 15

ZF2/ZF3 SSR Power Controller Safety Instructions

Rev 2 Ametek HDR Power Systems 1

SAVE THESE INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS

WARNING

Observe all warnings and cautions in this manual. Failure to do so may result in serious injury or death.

Refer all service to properly trained and qualified service personnel. Never work alone.

Lethal voltages exist on exposed heat sinks even if the power controller is turned off. Remove power and lock

out power before attempting any service.

This manual contains important safety instructions that must be followed during the installation and

maintenance of the SCR Power controller. Read this manual thoroughly before attempting to operate this

Power controller.

An appropriate branch circuit fused disconnect or circuit breaker with this Power Controller is required to

ensure the safety of operating personnel.

CAUTION

HAZARDOUS VOLTAGES exist at the Power Controller Line and Load terminals, AT ALL TIMES, when input

voltage is connected. This condition exists even when the Power Controller is set to deliver zero output.

Printed circuit boards contain sensitive components that can be damaged by electrostatic discharge (ESD).

Observe precautions for handling electrostatic sensitive devices. Reference Maintenance and Troubleshooting

Chapter of this manual for details

In case of fire, use a dry chemical fire extinguisher to put out the fire. Using a liquid fire extinguisher may

cause electric shock.

The SCR Power Controller makes use of components dangerous for the environment (electronic printed circuit

boards, electronic components). The components removed must be taken to specialized collection and

disposal centers.

E151547

100kA SCCR

IEC 947-5-1

Made in U.S.A.

Safety Instructions ZF2/ZF3 SSR Power Controller

2 Ametek HDR Power Systems Rev 2

ZF2/ZF3 SSR Power Controller Options

Rev 2 Ametek HDR Power Systems 3

CHAPTER 1 - Description

1.1 General Description

The ZF2 is three-phase 2-leg/4 SCR control and the ZF3 is a three-phase, 3-leg/6 zero-fired SCR

Power Controller. Each of these can operate with a wide variety of input signals and line voltages up

to 575 Vac and currents ranging from 15 through 70 amperes. The ZF1’s output voltage is

proportional to its input signal. HDR’s zero-fired SCR Power Controls utilize a variable-time-base that

helps maintain constant power to the load. The ZF1 SSR Series utilizes an isolated base Solid-State-

Relay (SSR) Module which contains two SCRs connected back to back. The firing circuit is based on a

common phase firing integrated circuit which includes soft-start for loads which have a large resistance

change due to temperature or start-up. Terminals are provided to ease installation.

1.2 Application

A variable time base firing circuit is used to provide precise control of power to resistive loads. These

units should never be used on inductive loads. However, they are versatile enough to be used in

place of mechanical contactors and mercury relays on dryers, kilns, ovens, environmental chambers,

extruders, molding equipment, and other types of equipment which uses resistive heat.

1.3 Specification

Specifications for the ZF2/ZF3 SSR power controller are given in Tables 1.1 and 1.2.

Table 1.1 ZF2/ZF3 Model Number Breakdown

ZF2 (or ZF3) – 480 – 25 – CL – FK – 01

NOTE: * Requires 24 Vac Transformer Option

1.4 Option NO/NC (Thermostat)

Heatsink Thermostats (Option NO or NC) provide a dry contact either Normally Open (NO) or Normally

Closed (NC).

1.5 Option FK (Fuse Kit)

The Fuse Kit (Option FK) consists of a Semi-Conductor Fuse and a fuse block. It is the user's

responsibility to mount this fuse kit and connect in series with the Line of the Power Controller.

1.6 Option TX (24 Vac Transformer)

The ZF1 requires 24 Vac @ 3VA control power for Voltage or Pot Command signal. Appropriate sized

transformer (Option TX) is available with 120, 240, 400, 480 or 600 Vac primaries.

120 Vac - 120

240 Vac - 240

400 Vac - 400

480 Vac - 480

575 Vac - 575

15 A rms - 15

25 A rms - 25

40 A rms - 40

Arms

N.O. Thermostat - NO

N.C. Thermostat - NC

Fuse Kit - FK

24 Vac Transformer - TX

Load Unbalance Alarm - UB

SCR Failure Alarm - SF

Can have multiple selections

4-20 mA (self powered) - C

4-20 mA - 01

*0-10 Vdc - 02

*0-5 Vdc - 03

*Manual Pot Input - 05

Others - xx

Options ZF2/ZF3 SSR Power Controller

4 Ametek HDR Power Systems Rev 2

Table 1.2 General Specifications of ZF2/ZF3 SSR Models

Input line voltage: *120, 240, 400, 480, or 575 Vac,

+10%, -15% , Two-phase or Three-Phase

Line frequency: 50 or 60 Hz

Current rating: *As indicated by model number (refer to Table 1.1)

Thermostat contact rating: 120 Vac, 5 A; resistive (optional)

Input Signal:

Voltage

Current

0 to 1.5 V (min); 0 to 10 V (max)

0 to 6 mA (min); 0 to 20 mA (max)

Control methods: 1. Potentiometer, 5 k, 1/2 watt (Customer-supplied).

2. Temperature or process controller *

Control signal input impedance:

Voltage input

Current input

1500 

500 Isolation:

From power to ground 1,500 Vac

Power SCRs protection:

Current surge Subcycle I² T semiconductor fuse - OPTIONAL

Transient voltage spikes (dv/dt)

SCCR Rating

Metal Oxide Varistor (MOV) across each SCR pair

100kA Miscellaneous:

Zero-firing timebase Variable see 3.1

Controls: ZERO and SPAN potentiometers; 10-turn, screwdriver-adjustable.

Approvals UL/cUL (E151547), CE

Ambient Temperature range:

Environment 32 ºF to 122 ºF ( 0 ºC to 50 ºC) surrounding air

Pollution degree 2

Overvoltage Category III

Storage 14 ºF to 158 ºF ( -10 ºC to 70 ºC)

Weight per unit Current Rating lbs kg lbs kg

: 15 through 40 A

70 A

2.5 lbs

5.7 lbs

1.1

2.6

3.6

1.63

4.1

Outline and mounting: See appropriate drawing in Appendix

* Specify with order

NOTE: The ZF2/ZF3 should be tested or operated with an adequate load since an open output will have line

voltage at the load connections.

1.7 Option UB (Load Unbalance Alarm)

The Load Unbalance Alarm Option (UB) monitors three phase currents and provides an alarm if the

load currents become unbalanced by more than the preset percentage. The limit is DIP switch

selectable and a form C relay is available for alarm along with diagnostic indicators. This option is

mounted external to ZF2/ZF3 Power Controller, reference 3-phase Load Unbalance & Shorted SCR

Alarm manual.

1.8 Option SF (SCR Failure Alarm)

The SCR Failure Alarm Option (SF) optional circuit monitors each SCR pair’s voltage drop and detects

when an SCR is shorted. Three green LEDs are lit when the SCRs are not shorted. If an SCR shorts,

the respective green LED will go out and the red alarm LED will light and the Form C relay will

energize. Relay output and terminals for connection are provided. This option is mounted external to

ZF2/3 Power Controller, reference 3-phase Load Unbalance & Shorted SCR Alarm manual.

ZF2/ZF3 SSR Power Controller Installation

Rev 2 Ametek HDR Power Systems 5

CHAPTER 2 - Installation

2.1 Mounting the ZF2/ZF3

Determine space and mounting hole requirements by referring to the outline drawing (in the Appendix)

that applies to your model’s current rating. Mount the unit so the line and load connections are at the

top and ensure that upward airflow over the heat sink fins is unrestricted.

2.2 Load Wiring

Connect the load to the proper terminals (refer to the input/output connections schematic in Appendix

A) using appropriately sized and insulated conductors. All input/output conductors should be stranded

copper wire only; minimum temperature rating is 75 ºC.

2.3 Line Wiring

Connect input lines from the fused disconnect or circuit breaker to the Line terminal (refer to the

input/output connections diagram) using appropriately sized and insulated conductors. (NOTE: Input

power should be routed through a fused disconnect or circuit breaker with a fuse or trip rating of 100%

to 125% of the current rating stamped on the nameplate of the ZF2 or ZF3 series unit.)

Torque Line and Load connection to 45 in-lbs.

If required, mount and connect the Control transformer (Option TX) per the schematic in Appendix A.

Select the appropriate Transformer voltage tap as shown in Table 2.1 and solder wires to the primary

terminals. An insulator is also provided to install between the transformer and the mounting plate.

Table 2.1 Control Transformer Voltage Wiring

Desired Voltage Primary Tap

120 120

208 240

220 240

240 240

380 400

400 400

415 400

480 480

575 575

WARNING - ELECTRIC SHOCK CAN KILL

HAZARDOUS VOLTAGES exist at the (LINE and LOAD) terminals when the

input voltage is connected. This condition exists even when the Controller is

set to deliver zero output. Always remove power and properly lock out power to

the unit before attempting any service, including the load.

WARNING

Branch circuit overcurrent protection required is to be provided in accordance

with the national and local codes of the inspecting authority.

Installation ZF2/ZF3 SSR Power Controller

6 Ametek HDR Power Systems Rev 2

2.4 Wiring Input Fuse

An Option (FK) Fuse Kit is available with high speed fuses (I²T) to protect the Solidstate Relays (SSR)

from Load shorts. The fuses are NOT meant for over current protection, separate branch circuit

protection is required. Mount the fuse blocks, reference Appendix G for mounting details.

2.5 Command Signal Input

HDR’s ZF2/ZF3 SSR Power Controllers have the capability of having a current, voltage or

potentiometer Command Signal input. On –C models it is current control only. If the Firing board is

capable of both voltage and current there is a 500 ohm 1/4W resistor is connected across terminals 1

and 2, for voltage command and remote potentiometer the 500 ohm resistor is removed. For Remote

control a potentiometer may be located on a remote panel near other controls related to the process

being powered by the ZF2/ZF3. The potentiometer should be rated 5 k, 1/2 Watt minimum.

Reference the schematic in Appendix A.

The Command Signal is NOT isolated from the Line. An isolated device such as an isolated PLC

output module to drive the command signal is required or damage can occur to the Power Controller.

2.6 Heatsink Thermostat Contacts

Normally-open (N.O.) or normally-closed (N.C.) thermostat is mounted to the heat sink when this

option is purchased. This thermostat, which close or open on high heat sink temperature (200 ºF),

may be used to initiate an alarm, shunt trip, or other device for SCR protection.

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