ZF1 Series 60-1200 Amp User Manual
Contents
1. Figure 11 OUTLINE AND MOUNTING 212 800 1000 8 1200 15682 DIA 6 PLACES 14 274 AIR FLOW 29 000 736 600 8 el 12 7 14 Figure 12 OUTLINE AND MOUNTING 273 60 and 90 through 225 FLOW 16 250 15 690 412 75 398 53 N A ON ZF3 UNITS 1 4 TURN CAPTIVE FASTENER FANS SHOWN REMOVED FOR CLARITY 15 8 250 209 55 a 31 000 787 400 34 925 14 375 365 125 14 375 365 125 SUPPLY 562 DIA 14 274 Q 38 1 375 fe 0 875 22 225 C C 9 0 9 p pem 7272 IC 16 6 je 9 17 250 438 15 19 000 482 60 Figure 13 OUTLINE AND MOUNTING 213 350 amp 500 A j NN N A 223 UNITS Figure 14 OUTLINE AND MOUNTING 213 650 N i Si 12. iii Table Figure NS SN NO NO 00 CN A RO Section 1 DESCRIPTION MODELS COVERED This manual covers the ZF1 ZF2 and ZF3 models rated 60 and 90 through 1200 amperes and options GENERAL DESCRIPTION The ZF is a single phase zero fired ZF SCR Power Control The ZF2 is three phase 2 leg 4 SCR control and the is a three phase 3 leg 6 SCR Power Controller Each of these will operate on voltages up to 575 Vac and accept most all standard process command signals Zero and Span multi turn potentiometers are provided to ease command signal calibration HDR s zero fired SCR Power Controls utilize a variable time base that helps maintain constant power to the load This variable time base also helps minimize temperature overshoot temperature fluctuations and helps extend the load element s life due to reduced thermal shock The power SCR assemblies consist of two SCRs connected back to back with a semiconductor fuse RC Snubber and MOV protection The ZF1 has one power assembly while the ZF2 has two and the ZF3 has 3 The firing circuit is based on common integrated circuits that provide very reliable operation Terminals are provided to ease installation Diagnostic indicators are included APPLICATIONS Zero Fired SCR Power Controls provide control of single or three phase power by the switching action of two SCRs connected back to back
3. MAI w gt Q lam 17 8 27 000 885 80 Figure 15 OUTLINE AND MOUNTING 213 800 1000 amp 1200 A 23 FAN AND THERMOSTAT WIRING Fans and thermostats are supplied on all units above 90A The user is responsible for supplying 120V AC unless otherwise specified for the fan Refer to Table 3 for the fan power requirements based on the unit s current rating Fan power should be connected to terminals 21 and 22 CAUTION The application of fan power should precede or coincide with the turn on of the line voltage source that is to be controlled by the disconnect switch Normally Open NO thermostats are standard on all units above 90A Normally Closed NC thermostats may be specified Normally Open or Normally Closed may be specified on the 60A model as an option Thermostats are on terminals 23 amp 24 Figure 16 FAN and THERMOSTAT TERMINALS 21 22 23 24 poH pos POWER TEMPERATURE 120VAC STANDARD 220 N C OPTIONAL OPTIONAL 19 Table 3 Fan Power
4. Power Controllers ILLUSTRATIONS Title Line Load Power Wiring 7 1 Line Load Power Wiring Line Load Power Wiring ZF3 Outline and Mounting ZF1 60 and 90 through 225 Outline and Mounting ZF1 350 and 500A Outline and Mounting ZF1 650A see Outline and Mounting ZF1 800 through 1200 Outline and Mounting ZF2 60 and 90 through 225A Outline and Mounting ZF2 350 and 500A Outline and Mounting 4 2 650 00 Outline and Mounting ZF2 800 through 1200A Outline and Mounting ZF3 60 and 90 through 225A Outline and Mounting 350 and 500A Outline and Mounting 650A Outline and Mounting ZF3 800 through 1200 Fan amp Thermostat T etmals 0 Remote Manual scusa ciii a Ru od ud eed Auto Manual Control ON OFF Contro ebur Firing Circuit Terminals amp DIP Switches
5. in each controlled phase By switching at the zero crossing point RFI Radio Frequency Interference is virtually eliminated Zero Fired controllers are versatile enough to be used in place of mechanical contactors and mercury relays on dryers kilns ovens environmental chambers extruders molding equipment and most other applications where resistive heating elements are used Normal Zero Fired SCR Power Controllers should never be used on inductive loads if this is a requirement contact HDR Power Systems about their ZFT3 3 Phase Zero Fired SCR Power Controller designed for firing into transformer primaries SPECIFICATIONS Refer to Table 1 for specifications on HDR s Zero Fired SCR Power Controls 1 2 1 3 1 4 Table 1 Specifications for HDR s Zero Fired SCR Power Controls 60 and 90 through 1200A CONTROL METHOD Zero firing of back to back SCRs per controlled phase VOLTAGE RATINGS 120 240 400 480 575V AC 50 60 Hz CURRENT RATINGS 60 90 120 180 225 350 500 650 800 1000 1200 A COMMAND SIGNAL 4 20ma 0 to 5VDC O to10VDC manual control ISOLATION 2500Vrms from line load to command signal 500Vrms to ground LINEARITY Output Power is linear to command signal fixed load VOLTAGE REG 1 for 10 line voltage change SCR PROTECTION Current surge semi conductor fuses transient voltage metal oxide varistor MOV and R C snubber ADJUSTMENTS Zero and Span multi turn DIAG INDICATORS Control pow
6. 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 is approximately 1 and the maximum off state current is approximately 15 ma The power controllers described in this instruction manual are designed to operate in a pollution degree 2 environment HAZARDS EXIST DANGEROUS VOLTAGES EXIST 22 Section 3 COMMAND SIGNAL CALIBRATION AND WIRING ZERO AND SPAN ADJUSTMENTS All ZF series SCR Power Controllers have both Zero and Span potentiometers used for matching the SCR Power Control and the Command Signal The Zero control is for the low end input min output adjustments while the Span Control is used for the high end input max output The Zero control has both negative and positive voltages available making it usable as a manual or zero control By turning the control clockwise the output will increase proportionally to the adjustment Turning it counter clockwise will decrease or zero the output The Span control is used to adjust the maximum desired output 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 COMMAND INDICATOR The Command Indicator is a green Light Emitting Diode LED located on the front cover of the unit The brilliance of this LED will change with the Command Signal Th
7. 04V A 50 Hz 3 6A 432V A 60 Hz 1000 4 2A 504VA 50 2 3 6A 432V A 60 Hz 1200A 4 24 504VA 50 2 3 6 432V A 60 Hz 20 INPUT LINE VOLTAGE CHANGES All units are shipped wired for the line voltage specified on the order If some other voltage is required it is normally a simple matter to change it Open the door on the Power Control and locate transformer T1 Unsolder and move the white black wire to the appropriate voltage tap On newer units starting September 2000 DIP switches have been added for selecting either 50 or 60 Hz Operation WARNING Hazardous voltages exist at the power controller heat sinks and at the load at all times when the input voltage is connected This condition exists even when the controller is set to deliver zero output SAFETY ISSUES The rated operational voltage of each power controller is shown on its nameplate ie 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 21 24 The voltage drop across the switching semiconductor while in the conducting mode is approximately 1 5 volts and Is somewhat a function
8. 45 10 Figure 7 OUTLINE AND MOUNTING 211 800 1000 amp 1200 Figure 8 OUTLINE AND MOUNTING 272 60 and 90 through 225 12 50 317 5 c 10 00 O 254 0 16 25 89 41275 398 53 8 500 215 9 AIR FLOW 1 18 375 20125 466 725 511 175 0 875 Figure 9 OUTLINE AND MOUNTING 212 350 8 500 F 22 225 5 22 225 12 s 6 KY 2 5 2 iS N 1 8 6 11 17 250 438 15 19 000 482 8 562 DIA 14 274 Figure 10 OUTLINE AND MOUNTING 212 650 562 DIA 8 PLACES 14 274 13 250 285 75 l I I II i 1 I x iH x I 1 1 1 1 l 22 000 23 000 558 800 584 200 1 1 I dl be I 13
9. INSTALLATION OPERATION and MAINTENANCE MANUAL MODEL ZF1 ZF2 and ZF3 rated 60 and 90 through 1200A SINGLE PHASE and THREE PHASE 2 or 3 LEG CONTROL SCR POWER CONTROLS UL cUL FILE NUMBER E151547 CE See last page of manual for CE Declaration Conformity AMETEK HDR POWER SYSTEMS 3563 INTERCHANGE ROAD COLUMBUS OH 43204 TEL 614 308 5500 TOLL FREE 1 888 797 2685 FAX 614 308 5506 AMETEK HDR POWER SYSTEMS SCR Power Controls Systems amp Power Supplies Dear Client On behalf of allof AMETEK HDR s employees 1 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 Controlneeds 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 Zoe 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 Date Added DIP Switch information Added EMC to CE Declaration Page Change Various 1 8 00 31 2 11 00 NOTE ALL SPECIFICATIONS SUBJECT CHANGE WITHOUT PRIOR NOTICE AMETEK HDR POWER SYS
10. 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 SCR Power Controller and check for corrosion and tightness of the power connections If any corrosion is evident clean the cable and connector and reconnect making sure to tighten according to our torque specifications in Table 2 STATIC PRECAUTIONS WHEN SERVICING When servicing the Firing Circuit Printed Circuit Board PCB damage can occur due to static electricity Always use a wrist strap grounded through a 1 megohm resistor Transport the PCB in a static shielding bag Caution in handling the PCB can help prevent any further damage to the PCB If you are not familiar with static precautions consult the factory for additional details TROUBLESHOOTING TYPICAL SYMPTOMS Any one of the following symptoms usually indicate a problem with the SCR Power Controller 28 4 1 4 2 4 3 4 4 1 No output regardless of the input 2 Full output regardless of the input 3 Output is not variable from zero to full Refer to Table 4 for help in troubleshooting Table 4 TROUBLESHOOTING Cause Solution 1 Open Fuse Disconnect power and check the fuse Replace if faulty If not contact the factory 2 Shorted SCR Disconnect power and check the SCRs Measure the resistance across the pair of SCRs the load must di
11. Requirements Model ZF1 Rating Power Requirements 60A N A 90A 21A 25VA 50 Hz 19A 23VA 60 Hz 120A 21 25VA 50 Hz 19 23VA 60 Hz 180A 21A 25VA 50 Hz 19A 23VA 60 Hz 225A 21A 25VA 50 Hz 19A 23VA 60 Hz 350A 21A 25VA 50 Hz 19A 23VA 60 Hz 500A 21A 25VA 50 Hz 19A 23VA 60 Hz 650A 1 4A 168VA 50 Hz 1 2 144VA 60 Hz 800A 1 4A 168VA 50 Hz 1 2 144VA 60 Hz 1000 1 4A 168VA 50 Hz 1 2A 144VA 60 Hz 1200 1 4A 168VA 50 Hz 1 2A 144 60 Hz Model ZF2 Rating Power Requirements 60A N A 90A 21A 25VA 50 Hz 19A 23VA 60 Hz 120A 21A 25VA 50 Hz 19A 23V A 60 Hz 180A 21A 25VA 50 Hz 19A 23V A 60 Hz 225A 21A 25 50 Hz 19A 23V A 60 Hz 350A 42A 50V A 50 Hz 38A 46 60 Hz 500A 42A 50V A 50 Hz 38A 46 60 Hz 650A 2 8A 336VA 50 Hz 2 4A 288VA 60 Hz 800A 2 8A 336VA 50 Hz 2 4A 288VA 60 Hz 1000A 2 8A 336V A 50 Hz 2 4 288VA 60 Hz 1200 2 8A 336V A 50 Hz 2 4 288VA 60 Hz Model ZF3 Rating Power Requirements 60A N A 90A 42 50V A 50 Hz 38A 46V A 60 Hz 120A 42 50V A 50 Hz 38A 46V A 60 Hz 180A 42A 50V A 50 Hz 38A 46V A 60 Hz 225A 42 50V A 50 Hz 38A 46V A 60 Hz 350A 63A 76V A 50 Hz 57A 69V A 60 Hz 500A 63A 76V A 50 Hz 57A 69V A 60 Hz 650A 4 2A 504V A 50 Hz 3 6A 432V A 60 Hz 800A 4 2A 5
12. TEMS COPYRIGHT 2003 TABLE OF CONTENTS Title Section 1 DESCRIPTION 1 General Description Desa editus i ni Oper Diagnostic Indicators Section 2 INSTALLATION a u ele Line Load Power Wiring van e a Fan and Input Line Voltage Safety Issues21 Section 3 COMMAND SIGNAL CALIBRATION AND WIRING Zero and Span Command Isolated and Non Isolated Inputs Remote Manual Process Command Signal Auto Marital 0 1X I C 6 Shutdown sable Section 4 MAINTENANCE Environmental Concerns Line Load Power Connections Static Precautions when Servicing Troubleshooting Typical Symptoms Para 1 1 1 2 1 3 1 4 1 5 1 6 1 7 2 1 2 2 2 3 2 4 2 5 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 4 1 4 2 4 3 4 4 Section 5 SERVICE AND PARTS Customer 0 Spare Parts dt ii Warranty TABLES and ILLUSTRATIONS TABLES Title 8 Lug Size Torque Information 2 kada oret Fan Power Requirements Troubleshooting Zero Fired SCR
13. e brilliance increases with an increased Command Signal and decreases with a decreased Command Signal The LED is usuable with 4 20ma Command Signals only and will be bypassed for other signals ISOLATED AND NON ISOLATED INPUTS The Firing Circuit has the capability of having either an optically isolated or non isolated Command Signal input The Power Controller will always be shipped with an isolated input unless specified otherwise known exception is a Manual Control input The standard input impedance is 500 ohms for isolated and 1500 ohms for non isolated An isolated input can be changed to a non isolated input by unsoldering jumpers J1 and J2 on the firing circuit and moving them to the non isolated position on the firing circuit On newer units starting September 2000 DIP Switch 1 replaces J1 amp J2 The isolated input works best with an offset Command Signal such as 4 20ma however it will work with both offset and zero based Command Signals Zero based Command Signals may have a small amount of non linearity input to output at the low end This normally is not a problem on closed loop systems 23 3 1 REMOTE MANUAL CONTROL Some applications only require a manual control input and not a closed loop input from a process controller The power controller is designed to accept a remote manual control input refer to Figure 17 for connections Adjustments are simple and quick but first verify that the firing circuit is set
14. er command signal blown fuse AMBIENT TEMP Operating 0 50 C Storage 10 70 C AGENCY APPROVALS UL cUL Listed amp CE Compliant 1 5 OPTIONS Available ZF1 options Over temperature thermostats are available as normally open NO or normally closed NC Thermostats are included on 90 through 1200 ampere units as standard equipment specify NO or NC Either normally open or normally closed thermostats are available as an option on units rated 60 amperes include NO or NC in your part number when specifying Mechanical Line Load lugs are standard equipment on the 60 through 225 ampere rated units They are available for units rated 350 through 1200 amperes as an option Include LG in your part number when specifying The following options are available for the ZF2 and ZF3 models Over temperature thermostats are available as normally open NO or normally closed NC Thermostats are standard equipment on units rated 90 through 1200 amperes but needs to specified as NO or NC Ifnot specified NO will be supplied Both are available as an option on 60 ampere rated units but must be specified 2 Mechanical Line Load lugs are available as an option on units rated 350 to 1200 amperes and are specified by adding LG to the Power Control s model number Mechanical lugs are standard on units rated 60 ampere but must be specified NO or NC normally open will be supplied if not specified An Unbalanced Load alarm UB is avai
15. er 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 customer 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 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 NOEVENT WILL AMETEK HDR BE LIABLE FOR INCIDENT OR CONSEQUENTIAL DAMAGES NOR IN ANY EVENT SHALL AMETEK HDR S LIABILITY EXCEED THE UNIT PRICE OF ANY DEFECTIVE PRODUCT OR PART 30 5 2 POWER SYSTEMS EC DECLARATION OF CONFORMITY AMETEK HDR POWER SYSTEMS 3563 Interchange Road Columbus Ohio 43204 USA WE Declare under our sole responsibility that the products listed below and bearing the CE label SCR power controllers with the follo
16. gure 1 LINE LOAD POWER WIRING 271 MODELS 1 PHASE LINE LOAD INPUT L2 Figure 2 LINE LOAD POWER WIRING ZF2 MODELS DELTA OR 3 WIRE WYE LOAD 3 PHASE LINE INPUT Figure 3 LINE LOAD POWER WIRING ZF3 MODELS DELTA OR 3 4 WIRE WYE LOAD 3 PHASE LINE INPUT Figure 4 OUTLINE AND MOUNTING 7 60 and 90 through 225 UP 1 4 TURN CAPTIVE FASTENER 16 25 15 69 412 75 398 53 9 25 235 Figure 5 OUTLINE AND MOUNTING 211 350 amp 500 10 000 215 9 E 09 20 125 ona 75 18 37 466 725 1 0875 22 225 0 875 22 225 e 562 DIA HOLES 14 274 13 000 330 2 14 750 374 65 g Figure 6 OUTLINE AND MOUNTING ZF1 650 A 562 DIA 6 PLACES 14 274 11 500 292 1 22 000 23 000 558 800 584 200 2 0 506 1 12 7 15 750 te 0 400 05 12 7 16 750 425
17. lable as an option Add UB to the model number when ordering a ZF2 or ZF3 A Shorted SCR Failure alarm SF is available as an option Add SF to the model number when ordering OPERATION HDR s Zero Fired SCR Power Controls control power by the switching action of two SCRs connected in a back to back configuration in each controlled phase The gating of these SCRs is synchronized with the line frequency either 50 or 60 HZ by the zero crossing detector built into the firing circuit Zero Fired SCR Power Controls turn the two SCRs in each phase on alternately as the incoming power passes through the 0 point of the sine wave The length of time these stay turned on is determined by the firing circuit and is based upon the input command signal The variable time base VTB firing circuit ensures that the off time number of off cycles is minimized for any command signal level This helps ensure load power as constant as possible while minimizing temperature overshoot temperature fluctuations and helps extend heater element life by avoiding thermal shock and mechanical stress DIAGNOSTIC INDICATORS Light Emitting Diodes diagnostic indicators LEDs are provided for aid in start up or maintenance A Control Power On indicator Red lights when the power controller has power applied The Command Signal indicator Green varies in brilliance with command signal s input level A Blown Fuse indicator Yellow is provided for each semiconductor fu
18. sconnected the resistance should be infinite in both directions If a short is indicated replace the defective SCR or return the unit to the factory 3 Defective Firing Circuit Disconnect power and unplug the Firing Circuit Order a replacement or return the Power Controller to the factory NOTE Virtually any failures of SCRs or Fuses on Zero Fired equipment can be attributed to short circuits in the load or loose power connections that cause arcing or sparking WARNING Always disconnect the power source prior to attempting to service the equipment 29 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 5 00 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 SPARE PARTS Inside Sales should be contacted for any spare parts orders 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 order number and parts required A purchase order numb
19. se and lights when the corresponding fuse blows 1 6 1 7 Section 2 INSTALLATION MOUNTING Prior to mounting verify the voltage and current rating of the SCR Power Control the information is provided on the unit s nameplate Determine the mounting dimensions from the outline drawings Figures 4 through 15 Mount the Power Controller with the line load terminals to the top so that air flow is upward through the heat sink fins Ensure that air flow is unrestricted Keep in mind that high current units require large input output cable Allow plenty of room LINE LOAD POWER WIRING Connect the line load using appropriately sized and insulated wire cable per NEC based on the voltage and current rating of the Power Control Cable lugs are provided on units rated 60 through 225A ratings above 225A have bus bar connections or optional mechanical lugs Refer to Table 2 for lug sizes and torque information WARNING Branch circuit overcurrent protection required to be provided is accordance with the national and or local code of the inspecting authority or equivalent Table 2 Lug Size Torque Information 60 to 225 ampere Size Wire Cable Torque 1 8to 0 AWG 45 in Lbs 1 8to 0 AWG 45 in Lbs 1 810 0 AWG 45 in Lbs 1 6to 250 MCM 250 in Lbs 1 6to 250 MCM 250 in Lbs Model 60A 90A 120A 180A 225A U L requires 75 C rated wire minimum for all power connections NOTE 2 1 2 2 Fi
20. t shuts off Now set the input contact to the closed position and adjust the Span control clockwise until the unit s output is at the desired maximum output level Repeating of this procedure may be necessary due to some interaction between the Zero and Span controls Figure 19 ON OFF CONTROL ESSERE SEES INPUT CONTACT SHUTDOWN Disable 26 3 7 3 8 When it is necessary to shutdown or disable the output it is a simple matter Connect a dry contact closure between terminals 3 and 4 of the firing circuit When it is closed the power control will be shut off Figure 20 FIRING CIRCUIT TERMINALS amp DIP SWITCHES 26 QUTD ae DE UMPERED 1 gt INPUT OFF WHEN COMMAND SHORTED AU OUT SIGNAL AL CONTROL mira ie id ck ISOLATED C1 oer et I m SW 50M1 62L MOUN ISOULRTED LzZ 21 Section 4 MAINTENANCE ENVIRONMENTAL CONCERNS Always verify that the SCR Power Controller is mounted in a clean dust free environment Clean the heat sink s and printed circuit board periodically so no dust and or dirt accumulates on the unit Dust and or dirt on the heat sink fins can prevent proper airflow causing overheating of the semiconductors Conductive dust and or dirt can cause shorts or arcing which can cause damage to the unit Always size your enclosure so that a 50 C maximum internal ambient temperature is never exceeded WARNING DISCONNECT ALL SOURCES OF
21. the unit s output is at zero Next have the process controller s output set at maximum and adjust the Span control for the maximum desired output As with the Remote Manual Control some interaction between controls does exist so repeating this procedure may be necessary AUTO MANUAL CONTROL On closed loop processes it may be desirable to be able to operate the power controller manually The HDR power controller has this capability designed into it Connect the Command Signal a Remote Manual control and an Auto Manual switch as shown in Figure 18 Make adjustments as stated for the Process Command Signal with the Auto Manual switch in the Auto position By switching to the Manual position the Remote Manual control operates Figure 18 AUTO MANUAL CONTROL Fa Ep E E v 7 RES SIGNAL NOTE Some non linearity will occur with the Manual Control 25 3 6 ON OFF CONTROL Some applications require that a simple ON OFF type control be used The power controller can be used in these simple applications It can be connected for turn on by a contact closure For on off control wire the contact according to figure 19 Once the wiring is complete turn on the input power Set the input contact to open and adjust the Zero control clockwise until the unit comes on then adjust counter clockwise until the unit jus
22. up for non isolated input and that R6 on the ZF1 R7 on the ZF2 or R5 on the ZF3 has been removed On newer units starting September 2000 DIP Switch 2 has been added to make this conversion easier Make sure it is in the 1 5K position Next start with the Remote Manual Control in the zero counter clockwise position apply power to the Power Control Adjust the Zero Control so the Power Control s output just starts to come on then adjust it counter clockwise so the unit s output is at zero Now adjust the Remote Manual Control to the full output clockwise position and adjust the Span Control until the maximum desired output is reached This procedure may have to be repeated due to some interaction between the Zero and Span controls Figure 17 REMOTE MANUAL CONTROL 5 5 2505 PEAK e Zn DIK 906369 3 ED 69 REMOTE MANUAL CONTROL NOTE Use voltmeter to monitor the output voltage flickering is common at any setpoint other than zero or full output Some load must be present when making adjustments or taking voltage measurements 24 3 4 PROCESS COMMAND SIGNAL Process command signals can be either offset or zero based as discussed earlier Simply connect the command signal to terminals 1 and 2 on the firing circuit and adjust the Zero and Span controls Adjustments are easy Simply have the process controller s output set at minimum and adjust the Zero control so
23. wing 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 70 90 and 120A SHZFI SHPFI 15 30 40 60 SHZE2 SHZF3 SHPF3 15 25 30 60 90 120 180 and 225A SCZFI 50271 15 25 40 and 65A Type To which this declaration relates is in conformity with the technical requirements of the following IEC 947 5 1 1990 03 IEC 73 23 EEC 1973 02 IEC 529 2nd Edition 1989 11 IEC 89 336 EEC 1989 05 All phase fired PF controllers will require line filters and possibly shielded cables to meet the EMC requirements Low voltage switchgear No and controlgear Year Low Voltage Directive No Year Degrees of protection provided by enclosures IP Code Year Electromagnetic Compatibility EMC Year Warning Environmental protection classification IPOO for mounting inside an enclosure Characteristics are according to manufactures specifications Name George A Sites Title Vice President Date November 10 2000 Declaration written in accordance with I S O IEC 22 Guide 31 documents Title Note
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