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).
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.
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.
4-3TROUBLESHOOTING 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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Page 31
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