Grieve Corporation ZF1-15 Installation Manual

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INSTALLATION, OPERATION and
MAINTENANCE MANUAL MODEL ZF1, ZF2 and ZF3 rated 15, 25, 40 & 70 AMP
SINGLE and THREE PHAS E - 2 or 3 LEG CONTROL
SOLI DSTATE RELAY (SSR) POWE R CO NTROLS
UL/cUL FILE NUMBER – E151547
CE – See last page of manual for CE Declaration of Conformity.
AMETEK HDR POWER S YS TEMS
3563 INTERCHANGE ROAD COLUMBUS, OHIO 43204
TEL: 614-308-5500 TOLL FREE: 1-888-PWR-CNTL (797-2685)
FAX: 614-308-5506
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SCR Power Controls/Systems & 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 b el i ev e A METEK H DR rep resen ts the b es t overal l sol uti on to y our SCR Power C ontrol n ee ds i n t he in du st ry toda y. We do this by pro viding a quality manufactured reliab le un it wit h 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
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
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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 2003 AMETEK HDR POWER SYSTEMS
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TABLE OF CONTENTS
Para.
Title Page
Section 1 - DESCRIPTION
1-1 Models Covered...................................................................................................1
1-2 General Description..............................................................................................1
1-3 Applications.........................................................................................................1
1-4 Specifications.......................................................................................................1
1-5 Options................................................................................................................2
1-6 Operation.............................................................................................................2
Section 2 - INSTALLATION
2-1 Mounting.............................................................................................................5
2-2 Line/Load Power Wiring......................................................................................5
2-3 Safety Issues........................................................................................................6
Section 3 - COMMAND SIGNAL CALIBRATION
3-1 Zero and Span Adjustments..................................................................................19
3-2 Command Indicator..............................................................................................19
3-3 Remote Manual Control.......................................................................................19
3-4 Process Command Signal.....................................................................................20
Section 4 - MAINTENANCE
4-1 Environmental Concerns ......................................................................................24
4-2 Line/Load Power Connections .............................................................................24
4-3 Troubleshooting Typical Symptoms.....................................................................24
Section 5 - SERVICE AND SPARE PARTS
5-1 Customer Service.................................................................................................26
5-2 Spare Parts...........................................................................................................26
5-3 Warranty..............................................................................................................26
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TABLES and ILLUSTRATIONS LIST
TABLES
Table
Title Page
1 Specifications............................................................................................................. 1
2 % Output Voltage at Various Input Command Levels................................................3
3 Fusing Requirements.................................................................................................. 6
4 Minimum/Maximum Currents .................................................................................... 7
ILLUSTRATIONS
Figure Title Page
1 Line/Load Power Wiring ZF1 Models........................................................................8
2 Line/Load Power Wiring ZF2 Models........................................................................8
3 Line/Load Power Wiring ZF3 Models........................................................................9
4 Outline & Mounting Dimensions – ZF1 15, 25 & 4 0A.............................................10
5 Outline & Mounting Dimensions – ZF1 70A............................................................11
6 Outline & Mounting Dimensions – ZF2 15, 25 & 40A .............................................12
7 Outline & Mounting Dimensions – ZF2 70A............................................................13
8 Outline & Mounting Dimensions – ZF3 15, 25 and 40A...........................................14
9 Outline & Mounting Dimensions – ZF3 70A............................................................15
10 24 VAC Transformer Dimensions & Schematic........................................................16
11 Single-Phase Fuse Block Dimensions.......................................................................17
12 Three-Phase Fuse Block Dimensions ........................................................................18
13 Remote Manual Control (-V) Models.......................................................................21
14 Process Command Signal (-V) Models.....................................................................22
15 Process Command Signal (-C) Models.....................................................................23
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DRAWING LIST
Schematic, ZF1 15 Thru 40A (-C).................................................................................S2710000
Schematic, ZF1 15 Thru 40A (-V)................................................................................. S2710001
Schematic, ZF1 70A (-C).............................................................................................. S2710079
Schematic, ZF1 70A (-V)..............................................................................................S2710080
Schematic, ZF1-C Firing Circuit....................................................................................S2078000
Assembly, ZF1-C Firing Circuit....................................................................................M2078000
Schematic, ZF1-V Firing Circuit.................................................................................... S2079000
Assembly, ZF1-V Firing Circuit....................................................................................M2079000
Schematic, ZF2 15 thru 40A (-C)..................................................................................S2710017
Schematic, ZF2 15 thru 40A (-V)..................................................................................S2710018
Schematic, ZF2 70A (-C)..............................................................................................S2710081
Schematic, ZF2 70A (-V)..............................................................................................S2710082
Schematic, ZF2-C Firing Circuit....................................................................................S2081000
Assembly, ZF2-C Firing Circuit ....................................................................................M2081000
Schematic, ZF2-V Firing Circuit ................................................................................... S 2082000
Assembly, ZF2-V Firing Circuit ....................................................................................M2082000
Schematic, ZF3 15 thru 40A..........................................................................................S2710034
Schematic, ZF3 70A .....................................................................................................S2710083
Schematic, ZF3 Firing Circuit........................................................................................S2099148
Assembly, ZF3 Firing Circuit.........................................................................................M2099148
NOTE: If ful l si ze drawi ngs are required, contact HDR insi de sal es and r equ es t th e d es i re d d raw i n g(s ) by the drawing number listed above.
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Section 1 - DESCRIPTION
1-1 MODELS COVERED
This manual covers the ZF1, ZF2 and ZF3 models rated 15, 25, 40 & 70 amperes and their options.
1-2 GENERAL DESCRIPTION
The ZF1, 2 and 3 models are solid-state, single and three-phase, zero-fired (ZF) So lid s t a t e R ela y p o w e r co n t r o ls wh ich will op e ra t e o n lin e vo lt a g es u p to 600 VAC. They accept most all standard process comman d si gnal s and regul ate the outpu t v ol tage . Zero and Span Multi -turn potentiometers are provi ded to ease calib ration. An i sol ated 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-cro ssing detector. T he firing circuit is based on common integrat ed circuits that provides very reliable operation. Terminals are provided to ease installation.
1-3 APPLICATIONS
A vari abl e tim e base f i rin g circui t is used to provide precise control of power to resi s ti v e loads. These uni ts should n ever be used on i nducti ve l oads. However, they are v ers ati l e enough to be used in pl ace of m echan ical contactors and mercury rel ays on dry e rs, kil n s , ovens, environmental chambers, extruders, molding equipment, and other types of equipment which uses resistive heat.
1-4 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 & 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; Storage, -10 to 70C. AGENCY LISTING – 15, 25, 40A UL/cUL Listed, CSA Certified, CE Compliant. 70A UL/cUL, CE Compliant
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1-5 OPTIONS
Three opt ions are available: a Fuse Kit, a 24 VAC Contr ol 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 respons ibilit y to mount this fus e 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. Speci fy NO for n orm al l y open or NC for no r mally closed.
1-6 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 detect or built into the solid-state relay module sy nchronizes the gatin g of these SCRs with the line frequen cy (either 50 or 60 HZ). The firing circuit provides timing pulses to the SSR proportional to the command signal. T hese pulsed determine the output level. The output may be adjusted by a voltage or current signal from a process controller. Zero and Span controls all ow the user to calib rate the power controll er’s output to the process signal. Termin al s are also avail ab l e for connection of a remote manual potentiometer on the (­V) mo del.
The power controller regulates the output voltage by proportionally controlling the number of AC cy cles “on” v ersus the n umber “off”. Because the voltage is “turned on” at zero cr ossing, very little radio frequency interference (RFI) is generated and
WARNING
Hazardous vol tages exist at the power c ontr o ll e r heat sinks and at the load at all times when the input voltage is connec ted. This condi ti on ex i st s even when the controller is set to deliver zero output.
NOTE: On the (-V) models , the z ero c ontrol can be used as a m anual c ontr ol, or a r em ote manual control can be connected.
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the power factor (PF) is n ear un ity. Keep in m ind 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
Ma
Input
4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20
%
Output Voltage
0 10 30 41 53 59 64 68 71 76 80 85 88 91 95 98
100
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Table 2 shows the percent output voltage at various i nput comm and si gnal l evel s. The var iable time b ase firing c ircu it p icks the minimum len gth t ime base to maint ain as constant a power level to the heating elements as possible. By doing this, thermal shock and mech an i cal abus e to the heating elements i s reduced and the l i f e ex pectancy of the element should increase.
NOTE: The percent o utput 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.
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Section 2 - INSTALLATION
2-1 MOUNTING
Prior t o mounting, verify the voltage and current r ating of the power contr oller. The inf ormation i s provided on the n amepl ate located on the left si de of the uni t. Determine th e mounting dimensions from the outline drawing Figures 3, 4, 5, 6, 7 or 8. Mount the unit with line/load terminals to the to p 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 co ntr olle r. Refe r t o F igur e 10 for the c ont ro l tr ans forme r’s mou nting dimens ions and schematic. Use Figures 11 and 12 for single and three-phase fuse block dimensions.
2-2 LINE/LOAD POWER WIRING
Connect the lin e/load usi ng appropriately si zed and i nsul ated wire/cabl e per any nati on al or local codes based on the vo ltage and current rating of the power controller. Torque t he line/load power connections to 25 in-lbs. minimum. Refer to Figures 1, 2 or 3 for all power connections.
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 desire d to protect the SC Rs, fast c lear ing sem iconductor fuses must be added to t he system. Table 3 shows t he fuse voltage, fuse current, fuse maximum I2T rating and conditional shor t cir cuit cur rent (C SCA) rating for each of t he p ower c ont rol’s ratings.
NOTE: a minimum rat ing of 75 °C wire is requ ired by UL for all power connections to the power control.
WARNING
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TABLE 3
UNIT
CURRENT (A)
15A
25A
40A
70A
NOTE: The Conditional Short Circuit Current (CSCA) rating is the maximum current the fuse can safely clear and this rating m ust be hi gher than the current the branch ci rcui t can supply.
2-3 SAFETY ISSUES
The rated operational voltage of each power controller is shown on it’s nam eplate, i.e. 120V, 240V, 400V, 480V, or 575V. The power controller is designed to operate between +10% and –15% of this rated operational vol tage in an Over Voltage Category III environment.
Th e voltage drop across the swit ching semiconduct or wh ile in the conducting mode is approxim ately 1.5 volts and is somewhat a f uncti on of current. To calculate the power control’s power loss, multiply the load current times 1.5 time the number of controlled phases.
FUSE
VOLTAGE
700
700
700
700
Power control units are not suitable to provide isolation due to the use of semiconductor s and other compon en ts th at allow a small current to flow from line to load even when the unit is in the non­conducting mode.
FUSE
CURRENT
20
30
50
80
WARNING
FUSE
I2T
157
427
950
4085
CSCA
200,000
200,000
200,000
200,000
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Th e minimu m o pe ra t ion al c ur re nt an d t he maximu m o ff st a te cu rr e nt for eac h un it is shown in Table 4.
The power cont rols described in this instruction manual are designed to operate in a pollution degree 2 environment.
TABLE 4
UNIT
CURRENT
(A)
15A
25A
40A
70A
MINIMUM
OPERATING
CURRENT
(ma)
100
100
100
100
MAXIMUM
OFF
CURRENT
(ma)
15
15
15
15
HAZARDS EXIST
DANGEROUS VOLTAGES EXIST
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Figure 1 – LINE/LOAD POWER WIRING ZF1 MODELS
Figure 2 – LINE/LOAD POWER WIRING ZF2 MODELS
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Figure 3 – LINE/LOAD POWER WIRING ZF3 MODELS
Figure 4 - OUTLINE and MOUNTING DIMENSIONS ZF1 - 15, 25 & 40A
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Figure 5 – OUTLINE and MOUNTING DIMENSIONS ZF1 – 70A
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Figure 6 – OUTLINE and MOUNTING DIMENSIONS ZF2 – 15, 25 & 40A
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Figure 7 – OUTLINE and MOUNTING DIMENSIONS ZF2 – 70A
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Figure 8 – OUTLINE and MOUNTING DIMENSIONS ZF3 – 15, 25 & 40A
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Figure 9 – OUTLINE and MOUNTING DIMENSIONS ZF3 – 70A
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Figure 10 – 24 Vac Transformer
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Figure 11 – SINGLE-PHASE FUSE BLOCK DIMENSIONS
15/25 AMP
40/70 AMP
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Figure 12 – THREE-PHASE FUSE BLOCK DIMENSIONS
15/25 AMP
40/70 AMP
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3-1 ZERO AND SPAN ADJUSTMENTS
On (-V) models (voltage input) the Zero potentiometer has both positi ve and negati v e voltages available making it usable as a manual or zero cont rol. By turning the Zero control clockwise the unit's output voltage will increase proportionally to the adjus tment. Tu rnin g it count er-c loc kwise will decrease the out put, or zero t he 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 vol tage available and, therefore, can only be used for zeroing the output for a 4-20ma comm and si gnal . Because the power controll er pul ls i t’s operating power from the 4-20ma source, no other device can be series or parallel connected.
Th e S pa n p ot e nt io met er o n bo t h ( - V) & ( -C ) mo d els is u se d t o a dju st t he ma ximum o ut put lev el. It will ad jus t fo r e ith er a re mot e ma nua l co nt ro l or a c omma nd sig nal input. Clockwi s e adjustment i ncreases the output while counter-clockwise adj us tm ent decreases the output. Due to some i nteraction between controls, i t may be neces sary to repeat bot h t he zero and span adjustments.
3-2 COMMAND INDICATOR
The Command Indicator is a green Light Emitting Diode (LED) located between the Zero and Span controls. The flash rate of this LED will vary in synchronization with the o ut p u t o f t h e u n it . T he ra t e w ill be faste r wit h hig he r o utp u t s a nd slo w er w it h lo we r outputs.
3-3 REMOTE MANUAL CONTROL (-V MODELS O NLY)
NOTE: A remote manual control cannot be used on a (-C) model.
Star t with th e Z e ro C on tr ol se t app r ox ima tely a t mid r ota tion a n d th e S pa n Control s e t 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 counter­clockwise, adjust the Zero Control until the unit is just off. Next turn the remote manual contro l fully clockwise and adjust the Span Contro l until the desired output voltage is reached. T his procedure may have to be repeated since some interaction between the Zero and Span Controls ex ist. The exact setting of the zero and span controls can a f f ect the linearity, so be as precise as possible.
Section 3 - COMMAND SIGNAL CALIBRATION
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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. Conne ct the Com m and Sig nal wi th the (-) on term i na l 1 and th e (+) on term i n al 2. Ref e r to Figure 14 for (-V) Models, and to Figure 15 for (-C) Models. Then energi ze the un i t. Wit h the C omma nd S ig n a l a t minimu m, a d ju s t the Z e r o C ontr ol so t h e u n it is just off (zero o utput voltage); next, with the Command 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 so me interaction between the Zero and Span Contro ls.
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.
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Figure 13 - REMOTE MANUAL CONTROL (- V) MODELS
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Figure 14 - PROCESS COMMAND SIGNAL (-V) MODELS
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Figure 15 - PROCESS COMMAND SIGNAL (-C) MODELS
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4-1 ENVIRONMENTAL CONCERNS
Alway s v erif y that the power control is m ounted in a cl ean, dust free en v i ron m en t. C l ea n the heat sink(s) and printed circui t board periodical l y s o no dust or dirt accumulates on the unit. Dust or dirt on the heat si nk f in s can preven t proper airf l ow and he at d i ss i pa ti on causin g overheating of the sem i conductors. Conductive dust or dirt can cause shorts or arcing, which can cause damage to the unit.
DISCONNECT ALL SOURCES OF POWER TO TH E POW ER CO NT ROLLER PRIOR TO CLEANING. THE UNIT IS NOT SUITABLE FOR HOSE DOWN CLEANING. USE VACUUM, B RUSH OR LOW PRESS URE AIR.
4-2 LINE/LOAD POWER CONNECTIONS
Periodically turn the power off to the ZF1 and ch eck for corrosion and ti ghtness of the power co nnections. If any corrosion is evident, clean the cables and connectors and reconnect them. Tighten them to 25 in-lbs.
4-3 TROUBLESHOOTING TYPICAL SYMPTOMS
Any o ne o f th e fo llo win g p ro ble ms c an be r ep air ed in t he fie ld. Any ot he r p ro ble ms 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 po wer and check the fuse, replace the fuse if
faul ty. If the f use checks ok, verif y the 24 VAC control power on termi n al s 4 & 5 if the unit is a (-V) Mo del. If neither of these solve the problem, contact the factory.
2. Symptom - Full o utput regard less of co mmand sig nal le vel. Cause - Shorted SSR module or defective firing circuit. Solution - Readjust the zero and span controls. If this does not help, di sconnect
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.
Section 4 - MAINTENANCE
WARNING
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3. Symptom - T h e unit is not variable from 0 to full out put. Cause - Defective firing circuit. Solution - If neither of the first two symptom/solutions are the answer,
order a replacement firing circuit from the factory.
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5-1 CUSTOMER SERVICE
If you h ave operational p roble ms w hich can n ot be resolved using this manu al, please contact the Se rvi ce Departm en t at AMETEK HDR . Our n orma l w ork hour s ar e 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 an swer af ter hou r s a n d w e will return your call the next working day.
FAX: 614-308-5506. 24 hours per day automatic answering.
EMERGENCY: Pager 1- 800-759- 8888, PI N # 1245473.
5-2 SPARE PARTS
Inside Sales should be contacted for any spare parts order whether routine or emergency duri ng norm al workin g hours. Al l af ter hours requirem ents sh ou l d b e c al l e d in on our 614-308-5500 answerin g m achi ne. Pl ease have as much in f orm a ti on av a i l ab l e as possible pertaining to the model number, serial number, AMETEK HDR order number and parts required. A purchase order number should be available.
5-3 WARRANTY
AMETEK HDR warrants that the equipment delivered will be fr ee fro m defe ct s in workmanship and material for a period of five years from the date of shipment. AMETEK HDR will re pa ir o r r ep lace, 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 recei ved b y A METEK HD R w i th i n th e f iv e year wa rran ty pe ri od an d tha t the cus tomer re turns th e part to AMETEK HDR f rei gh t pai d both w ay s. Th i s w a rra n ty is not transf erable by t h e initial end us er.
AMETEK HDR MA KES N O OTHER WA RR ANTIES , EXPRE SS ED O R IM PL I ED (INCLUDING, WITHOUT LIMITATION, MERCHANTABILITY, FITNESS FOR PURPOSE, OR AGAINST INFRINGEMENT OF ANY PATENT) EXCEPT AS EXPRESSLY PROVIDE D HE RE I N.
Section 5 - SERVICE AND SPARE PARTS
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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 CONSEQUENT IAL DAMAGES, NOR IN ANY EVENT SHALL HDR'S LIABILITY EXC EED THE UNIT PRICE OF ANY DEFECTIVE PRODUCT OR P ART.
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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:
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 control gear Year: 1990-03 Low Voltage Directive No. IEC 73/23/EEC
Degrees of protection provided No. IEC 529-2nd Edition by enclosures (IP Code): Year: 1989-11
Electromagnetic Compatibility No. IEC 89/336/EEC (EMC) Year: 1989-05
(Environmental protection classification IP00 - for mounting ins ide an enclosure)
Note
: Characteristics are according to manufactures specifications.
EC DECLARATION OF CONFORMITY
ZF1, ZF2, ZF3, PF1, PF3 - 15, 25, 40, 60, 70, 90, 120, 180, 225, 350, 500, 650, 800, 1000 and 1200A. SHZF1, SHPF1 - 15, 30, 40, 60, 70, 90 and 120A SHZF2, SHZF3, SHPF3 - 15, 25, 30, 60, 90, 120, 180 and 225A SCZF1, SCPF1 - 15, 25, 40 and 65A
Year: 1973-02
Warning All phase-fired (PF) controllers will require line filters and possibly shielded cables to meet the EMC requirements.
Name: George A. Sites
Declaration written in accordance with I.S.O. – IEC/22 Guide.
Title: Vice President Date: November 9, 2000
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