ZF1 Series 15-70 Amp User Manual
Contents
1. 3 F sme RE rad e bn RIS RA M e PUER ERRARE 6 Minimum Maximum Currents ocio acne dies mite ae en ie 7 ILLUSTRATIONS Title Page Line Load Power Wiring ZF1 Models ee ee 8 Line Load Power Wiring ZF2 Models id diia 8 Line Load Power Wiring 9 Outline amp Mounting Dimensions 7 15 25 amp 4 0A 10 Outline amp Mounting Dimensions ZF 70 0 5 11 Outline amp Mounting Dimensions ZF2 15 25 amp 40 12 Outline amp Mounting Dimensions ZF2 70A eene 13 Outline amp Mounting Dimensions 15 25 and 40 14 Outline amp Mounting Dimensions 70A eene eene 15 24 VAC Transformer Dimensions amp Schematic 16 Single Phase Fuse Block Dimensions eene 17 Three Phase Fuse Block Dimensions i eap e lidia 18 Remote Manual Control V Models 21 Process Command Signal V 8 22 Process Command Signal C Models eene 23 ii DRAWING LIST Schematic ZF1 15 Thru 40A ee 527100002. Schematic 15 Thru 0 ute ise ev a ee cede ot 52710001 Schematic ZF1 70A EC tore Fen EE EE visse 52710079 Schematic GRENS EE Oe N EN 52710080 Schematic ZF1 C Firing CGU 52078000 Assembly ZF1 C Firing es ee ge das M2078000 schematic ZET V Firing CAECUS eoi GE EE EEE 52079000 Assembly Ss AA Ss 2079000 Schematic ZE2 15 thrg 40A Elsa 52710017 Schematic ZF2 tS thru ADA entire 52710018 Schematic ZE2 OA GE as en ERE 52710081 Schematic ZE2TOA EV 52710082 schematics ZB2 C Eins i ee EG 52081000 Assembly OC Faris CCUG EE M2081000 Schematic ZF2 V Firing CITGUI vida ie oss dee ran dai dos ES T 52082000 Assembly ZF2 V Firme oe EE M2082000 Schematic ZE 15 thri 40A ds 52710034 Schematic TOA esit tren tpe ia id 52710083 Schematic ZES Fine CAT CMIE eeu EE 52099148 Assembly ZF3 Firing v adda Pe M2099148 NOTE If full size drawings are required contact HDR inside sales and request the desired drawing s by the drawing number listed above iii 1 2 1 3 1 4 Section 1 DESCRIPTION MODELS COVERED This manual covers the ZF1 ZF2 and ZF3 models rated 15 25 40 amp 70 amperes and their options GEN
3. Emitting Diode LED located between the Zero and Span controls The flash rate of this LED will vary in synchronization with the output of the unit The rate will be faster with higher outputs and slower with lower outputs REMOTE MANUAL CONTROL V MODELS ONLY NOTE A remote manual control cannot be used on a C model Start with the Zero Control set approximately at mid rotation and the Span Control set minimum counter clockwise Connect a 5K ohm remote manual control as shown in Figure 13 With the unit energized and the remote manual control fully counter clockwise adjust the Zero Control until the unit is just off Next turn the remote manual control fully clockwise and adjust the Span Control until the desired output voltage is reached This procedure may have to be repeated since some interaction between the Zero and Span Controls exist The exact setting of the zero and span controls can affect the linearity so be as precise as possible 19 3 4 PROCESS COMMAND SIGNAL This procedure is similar to the Remote Manual Control procedure Start with the Zero Control set approximately at mid rotation and the Span Control set at minimum Connect the Command Signal with the on terminal 1 and the on terminal 2 Refer to Figure 14 for V Models and to Figure 15 for C Models Then energize the unit With the Command Signal at minimum adjust the Zero Control so the unit is just off zero output voltage next with the Command
4. Signal at full output adjust the Span Control so the output voltage is at the desired output level Repeating this procedure may be necessary due to some interaction between the Zero and Span Controls NOTE The V models will accept a 0 5 VDC 0 10 VDC 4 20 ma or a manual control input The C model will only accept a 4 20 ma input and cannot be series or paralleled with other units 20 Figure 13 REMOTE MANUAL CONTROL V MODELS INPUT OPTIONAL FUSE KIT FK LINE LOAD OPTIONAL CONTROL POWER XFORMER TX 2 1 MANUAL CONTROL 21 Figure 14 PROCESS COMMAND SIGNAL V MODELS INPUT UP TO 600VAC OPTIONAL FUSE KIT FK LINE LOAD OPTIONAL CONTROL POWER XFORMER TX ZF1 XXX XX V COMMAND SIGNAL 22 Figure 15 PROCESS COMMAND SIGNAL C MODELS INPUT UP TO 600 OPTIONAL FUSE KIT FK LINE LOAD ZF1 XXX XX C COMMAND SIGNAL 23 4 1 4 2 Section 4 MAINTENANCE ENVIRONMENTAL CONCERNS Always verify that the power control is mounted in a clean dust free environment Clean the heat sink s and printed circuit board periodically so no dust or dirt accumulates on the unit Dust or dirt on the heat sink fins can prevent proper airflow and heat dissipation causing overheating of the semiconductors Conductive dust or dirt can cause shorts or arcing which can cause damage to the unit WARNING DISCONNECT ALL S
5. Storage 10 to 70C AGENCY LISTING 15 25 40A UL cUL Listed CSA Certified CE Compliant 70A UL cUL CE Compliant 1 5 1 6 OPTIONS Three options are available a Fuse Kit a 24 VAC Control Transformer for the V Models and heat sink thermostat s The Fuse Kit Option FK consists of a Semi Conductor Fuse and fuse block It is the user s responsibility to mount this fuse kit The V models require 24 VAC 3VA control power An appropriately sized transformer Option TX is available with 120 240 400 480 or 575 VAC primaries Over temperature thermostats are mounted on each heat sink Specify NO for normally open or NC for normally closed OPERATION The power is controlled by the switching action of two SCRs connected in a back to back configuration in each controlled phase The zero crossing detector built into the solid state relay module synchronizes the gating of these SCRs with the line frequency either 50 or 60 HZ The firing circuit provides timing pulses to the SSR proportional to the command signal These pulsed determine the output level The output may be adjusted by a voltage or current signal from a process controller Zero and Span controls allow the user to calibrate the power controller s output to the process signal Terminals are also available for connection of a remote manual potentiometer on the V model WARNING Hazardous voltages exist at the power controller heat sinks and at the load a
6. are the answer order a replacement firing circuit from the factory 25 5 2 Section 5 SERVICE AND SPARE PARTS CUSTOMER SERVICE If you have operational problems which cannot be resolved using this manual please contact the Service Department at AMETEK HDR Our normal work hours are 8 a m to 3 30 p m U S A EASTERN TIME ZONE Monday through Friday TELEPHONE 1 888 PWR CNTL 797 2685 OR 614 308 5500 Our answering machine at 614 308 5500 will answer after hours and we will return your call the next working day FAX 614 308 5506 24 hours per day automatic answering EMERGENCY Pager 1 800 759 8888 PIN 1245473 SPARE PARTS Inside Sales should be contacted for any spare parts order whether routine or emergency during normal working hours All after hours requirements should be called in on our 614 308 5500 answering machine Please have as much information available as possible pertaining to the model number serial number AMETEK HDR order number and parts required A purchase order number should be available WARRANTY AMETEK HDR warrants that the equipment delivered will be free from defects in workmanship and material for a period of five years from the date of shipment AMETEK HDR will repair or replace at AMETEK HDR s option any part found defective during proper and normal use provided that written notice of the nature of the defect is received by AMETEK HDR within the five year warranty period and that the cu
7. 200 5 08 234 06 Figure 7 OUTLINE and MOUNTING DIMENSIONS ZF2 70A 12 1 281 X 1 000 MTG SLOTS ice 0 000 8 750 EE A 0 625 08 CU ONLY ST CU ONLY OR Figure 8 OUTLINE and MOUNTING DIMENSIONS ZF3 15 25 amp 40A 13 de WARNING WARNING WARNING E 0 200 em odpi Oy QUO KDE OLD DTD jo Wo EP lokWe LINE LOAD LINE LOA LINE LOAD Hor HOE IDR nas 1524 O QOR COMMAND INDICATOR 4 E W x gt gt 5 Lett HE octet betes 2 des Fr 4 350 n 515 4 350 515 4 350 0 200 13 08 13 08 110 49 5 08 RECOMMENDED 14 080 357 63 Figure 9 OUTLINE and MOUNTING DIMENSIONS ZF3 70 14 UP 281 X 1 000 MTG SLOTS 10 000 8 750 E 26 000 15 Figure 10 24 Vac Transformer IN ASLS VS AG TM AOtZ 0 NI 0060 6 0 062 OMVZZ 00706 290 vid 87 16 Figure 11 SINGLE PHASE FUSE BLOCK DIMENSIONS 3 000 MOUNT WITH 10 32 HARDW
8. 2003 AMETEK HDR POWER SYSTEMS Para 1 1 1 2 1 3 1 4 1 5 1 6 2 1 2 2 2 3 3 1 3 2 3 3 3 4 4 1 4 2 4 3 TABLE OF CONTENTS Title Section 1 DESCRIPTION Models COVeteu uelis de leto h a eed General D escrIptiorni iss pia DIOMIOMNS Ms Ss u A md MALE Operation sono hc La ei Gus n E ARE Co Section 2 INSTALLATION MOUSE ae a ux Line Eoad Power WI a CHR EAS S MEE tee Saec ISSUES ista e ea desde qe M Section 3 COMMAND SIGNAL CALIBRATION Zero and Span Adjustments serene Command Indie atop oM tube det a Remote Manual Control Process Command Signal eene n Section 4 MAINTENANCE Environmental Concerns 00 Line Load Power Connections Troubleshooting Typical Symptoms Section 5 SERVICE AND SPARE PARTS Customer Service ds RRR RE RR Spare Par iii Warranty ypas apana Table BRWN Figure ON tn D TABLES and ILLUSTRATIONS LIST TABLES Title Page Nie er bier ie OE N 1 Output Voltage at Various Input Command
9. ARE 15 25 AMP MOUNT WITH 8 32 HARDWARE 40 70 AMP Jy Figure 12 THREE PHASE FUSE BLOCK DIMENSIONS MOUNT WTH 10 32 HARDWARE 15 25 AMP 3 567 2 189 4 565 437 DIA BOTH ENDS 40 70 AMP 18 3 3 Section 3 COMMAND SIGNAL CALIBRATION ZERO AND SPAN ADJUSTMENTS On V models voltage input the Zero potentiometer has both positive and negative voltages available making it usable as a manual or zero control By turning the Zero control clockwise the units output voltage will increase proportionally to the adjustment Turning it counter clockwise will decrease the output or zero the output for a non zero based command signal Zero is mid rotation On C models 4 20ma current input only the Zero potentiometer has only the negative voltage available and therefore can only be used for zeroing the output for a 4 20ma command signal Because the power controller pulls it s operating power from the 4 20ma source no other device can be series or parallel connected The Span potentiometer on both V amp C models is used to adjust the maximum output level It will adjust for either a remote manual control or a command signal input Clockwise adjustment increases the output while counter clockwise adjustment decreases the output Due to some interaction between controls it may be necessary to repeat both the zero and span adjustments COMMAND INDICATOR The Command Indicator is a green Light
10. ERAL DESCRIPTION The ZFl 2 and 3 models are solid state single and three phase zero fired ZF Solidstate Relay power controls which will operate on line voltages up to 600 VAC They accept most all standard process command signals and regulate the output voltage Zero and Span Multi turn potentiometers are provided to ease calibration An isolated base Solid State Relay SSR module is used for power switching in each controlled phase This module contains two SCRs connected back to back and a zero crossing detector The firing circuit is based on common integrated circuits that provides very reliable operation Terminals are provided to ease installation APPLICATIONS 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 SPECIFICATIONS TABLE 1 CONTROL METHOD Zero firing of back to back SCRs in each phase VOLTAGE RATING Up to 600 VAC 1 or 3 Ph 50 60 Hz CURRENT RATING 15 25 40 amp 70 Arms COMMAND SIGNAL 4 20 ma 0 5 VDC 0 10 VDC Manual Control ISOLATION 2500 Vrms from line load to command signal to ground ADJUSTMENTS Zero and Span Multi turn AMBIENT TEMPERATURE Operating 0 to 50C
11. INSTALLATION OPERATION and MAINTENANCE MANUAL MODEL ZF1 ZF2 and ZF3 rated 15 25 40 amp 70 AMP SINGLE and THREE PHASE 2 or 3 LEG CONTROL SOLIDSTATE RELAY SSR POWER CONTROLS UL cUL FILE NUMBER E151547 CSA FILE NUMBER LR91210 CE See last page of manual for CE Declaration of Conformity AMETEK HDR POWER SYSTEMS 3563 INTERCHANGE ROAD COLUMBUS OHIO 43204 TEL 614 308 5500 TOLL FREE 1 888 PWR CNTL 797 2685 FAX 614 308 5506 AMETEK HDR POWER SYSTEMS SCR Power Controls Systems amp Power Supplies Dear Client On behalf of all of AMETEK HDR s employees I want to take this opportunity to thank you for purchasing an AMETEK HDR Power Systems SCR Power Control We believe AMETEK HDR represents the best overall solution to your SCR Power Control needs in the industry today We do this by providing a quality manufactured reliable unit with fast on time delivery and a competitive price All of our employees are dedicated to your success If you have any questions comments or concerns please call me toll free at 1 888 PWR CNTL 797 2685 Sincerely AMETEK HDR POWER SYSTEMS 24 06 George A Sites Vice President GAS be 3563 Interchange Road Columbus OH 43204 1400 USA Telephone 614 308 5500 1 888 PWR C NTL FAX 614 308 5506 REVISION PAGE Page Change Revision Date 28 1 Added EMC statement to EC Declaration 11 00 NOTE ALL SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE COPYRIGHT
12. MUM MAXIMUM UNIT OPERATING OFF CURRENT CURRENT CURRENT A ma ma 15A 100 15 25A 100 15 40A 100 15 70A 100 15 HAZARDS EXIST DANGEROUS VOLTAGES EXIST Figure 1 LINE LOAD POWER WIRING ZF1 MODELS 1 PHASE LOAL 24VAC NOT REQUIRED ON MODELS 24VAC LS Figure 2 LINE LOAD POWER WIRING ZF2 MODELS DELTA OR 3 WIRE WYE LOAD 3 PHASE 24VAC NOT REQUIRED ON C MODELS 24VAC L Figure 3 LINE LOAD POWER WIRING ZF3 MODELS DELTA OR 3 4 WRE WYE LOAD 3 PHASE 24VAC CONTROL POWER REQUIRED ON ALL ZF3 s RATED 15 25 40 amp 70 Figure 4 OUTLINE and MOUNTING DIMENSIONS ZF1 15 25 amp 40A WARNING HE 0 200 ES pes COMMAND INDICATOR 7 Bere aai ale Ee 4 350 110 49 4 500 6 000 114 3 152 4 0 750 19 05 b 0 200 5 08 Figure 5 OUTLINE and MOUNTING DIMENSIONS ZF1 70A 10 51075 DIN 0001 X 18 75 C CU ONLY TORQUE 45 IN LBS AVAC CLASS 2 000 01 08 78 m o 0068 Figure 6 OUTLINE and MOUNTING DIMENSIONS ZF2 15 25 amp 40A 11 0 200 5 08 COMMAND INDICATOR ra Va A Y ul V 0 a 4 500 6 000 114 3 152 4 0 750 1 32 4 350 515 13 08 RECOMMENDED 9 215 0
13. OURCES OF POWER TO THE POWER CONTROLLER PRIOR TO CLEANING THE UNIT IS NOT SUITABLE FOR HOSE DOWN CLEANING USE VACUUM BRUSH OR LOW PRESSURE AIR LINE LOAD POWER CONNECTIONS Periodically turn the power off to the ZF1 and check for corrosion and tightness of the power connections If any corrosion is evident clean the cables and connectors and reconnect them Tighten them to 25 in lbs TROUBLESHOOTING TYPICAL SYMPTOMS Any one of the following problems can be repaired in the field Any other problems require returning the power controller to HDR for servicing 1 Symptom No output Cause Open fuse or no 24 VAC control power on V Models Solution Disconnect the input power and check the fuse replace the fuse if faulty Ifthe fuse checks ok verify the 24 VAC control power on terminals 4 amp 5 if the unit is a V Model If neither of these solve the problem contact the factory 2 Symptom Full output regardless of command signal level Cause Shorted SSR module or defective firing circuit Solution Readjust the zero and span controls If this does not help disconnect the input power and remove the firing circuit Re energize if the output is on full replace the SSR module If the output is off then most likely the firing circuit is defective Consult the factory 24 Symptom The unit is not variable from O to full output Cause Defective firing circuit Solution If neither of the first two symptom solutions
14. l gear Year 1990 03 Low Voltage Directive No IEC 73 23 EEC Year 1973 02 Degrees of protection provided No IEC 529 2nd Edition by enclosures IP Code Year 1989 11 Electromagnetic Compatibility No TEC 89 336 EEC EMC Year 1989 05 Warning All phase fired PF controllers will require line filters and possibly shielded cables to meet the EMC requirements Environmental protection classification 00 for mounting inside an enclosure Note Characteristics are according to manufactures specifications Name George A WZ T Title Vice President Date November 9 2000 Declaration written in accordance with I S O IEC 22 Guide 28
15. ontrol TABLE 3 UNIT FUSE FUSE FUSE CURRENT A VOLTAGE CURRENT PT CSCA 15A 700 20 157 200 000 25 700 30 427 200 000 40 700 50 950 200 000 70 700 80 4085 200 000 NOTE The Conditional Short Circuit Current CSCA rating is the maximum current the fuse can safely clear and this rating must be higher than the current the branch circuit can supply 2 3 SAFETY ISSUES The rated operational voltage of each power controller is shown on it s nameplate i e 120V 240V 400V 480V or 575V The power controller is designed to operate between 10 and 15 of this rated operational voltage in an Over Voltage Category III environment WARNING Power control units are not suitable to provide isolation due to the use of semiconductors and other components that allow a small current to flow from line to load even when the unit is in the non conducting mode The voltage drop across the switching semiconductor while in the conducting mode is approximately 1 5 volts and is somewhat a function of current To calculate the power control s power loss multiply the load current times 1 5 time the number of controlled phases The minimum operational current and the maximum off state current for each unit is shown in Table 4 The power controls described in this instruction manual are designed to operate in a pollution degree 2 environment TABLE 4 MINI
16. stomer returns the part to AMETEK HDR freight paid both ways This warranty is not transferable by the initial end user AMETEK HDR MAKES NO OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION MERCHANTABILITY FITNESS FOR PURPOSE OR AGAINST INFRINGEMENT OF ANY PATENT EXCEPT AS EXPRESSLY PROVIDED HEREIN 26 THE REMEDY OF REPAIR OR REPLACEMENT IS CUSTOMER S SOLE AND EXCLUSIVE REMEDY AND WILL SATISFY ALL OF AMETEK HDR S LIABILITIES WHETHER BASED ON CONTRACT NEGLIGENCE TORT PRODUCT LIABILITY STRICT LIABILITY OR OTHERWISE IN NO EVENT WILL HDR BE LIABLE FOR INCIDENT OR CONSEQUENTIAL DAMAGES NOR IN ANY EVENT SHALL HDR S LIABILITY EXCEED THE UNIT PRICE OF ANY DEFECTIVE PRODUCT OR PART 21 AMETEK HDR POWER SYSTEMS EC DECLARATION OF CONFORMITY WE AMETEK HDR POWER SYSTEMS 3563 Interchange Road Columbus Ohio 43204 USA Declare under our sole responsibility that the products listed below and bearing the CE label Type SCR power controllers with the following model designations and current ratings ZF1 ZF2 ZF3 PF1 PF3 15 25 40 60 70 90 120 180 225 350 500 650 800 1000 and 1200A SHZFI SHPF1 15 30 40 60 70 90 and 120A SHZE2 SHZF3 SHPF3 15 25 30 60 90 120 180 and 225A SCZF1 SCPFI 15 25 40 and 65A To which this declaration relates is in conformity with the technical requirements of the following documents Title Low voltage switchgear No IEC 947 5 1 and contro
17. t all times when the input voltage is connected This condition exists even when the controller is set to deliver zero output NOTE On the V models the zero control can be used as a manual control or a remote manual control can be connected The power controller regulates the output voltage by proportionally controlling the number of AC cycles versus the number off Because the voltage is turned on at zero crossing very little radio frequency interference RFI is generated and the power factor PF is near unity Keep in mind that ZF units can only be used on resistive loads If an inductive load or a load with a large resistance change instantaneously or cold to hot is being used a phase fired PF power control should be used TABLE 2 OUTPUT VOLTAGE AT VARIOUS INPUT COMMAND LEVELS Table 2 shows the percent output voltage at various input command signal levels The variable time base firing circuit picks the minimum length time base to maintain as constant a power level to the heating elements as possible By doing this thermal shock and mechanical abuse to the heating elements is reduced and the life expectancy of the element should increase NOTE The percent output voltage for any given command signal Is affected by the exact setting of the zero and span potentiometers Table 2 is to be used only as a reference 2 2 Section 2 INSTALLATION MOUNTING Prior to mounting verify
18. the voltage and current rating of the power controller The information is provided on the nameplate located on the left side of the unit Determine the mounting dimensions from the outline drawing Figures 3 4 5 6 7 or 8 Mount the unit with line load terminals to the top so that airflow is upward through the heat sink fins Ensure that airflow is unrestricted Mount the fuse kit and the 24 VAC control transformer as close as possible to the power controller Refer to Figure 10 for the control transformer s mounting dimensions and schematic Use Figures 11 and 12 for single and three phase fuse block dimensions WARNING Branch circuit overcurrent protection is required to be provided in accordance with the national and or local code of the inspecting authority or equivalent If it is desired to protect the SCRs fast clearing semiconductor fuses must be added to the system Table 3 shows the fuse voltage fuse current fuse maximum RT rating and conditional short circuit current CSCA rating for each of the power control s ratings LINE LOAD POWER WIRING Connect the line load using appropriately sized and insulated wire cable per any national or local codes based on the voltage and current rating of the power controller Torque the line load power connections to 25 in Ibs minimum Refer to Figures 1 2 or 3 for all power connections NOTE a minimum rating of 75 C wire is required by UL for all power connections to the power c
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