Grieve Corporation ZF1-15 Installation Manual
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
CSA FILE NUMBER – LR91210
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
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
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
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
i
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
ii
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.
iii
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
1
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.
2
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
3
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.
4
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
5
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