Grieve Corporation ZF2 Installation Manual

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 CONTROL S

UL/cUL FILE NUMBER – E151547

CE – See last page of manual for CE Declaration of Conformity

AMETEK H DR POW ER S YS TEMS

3563 INTERCHANGE ROAD COLUMBUS, OH 43204

TEL: 614-308-5500 TOLL FREE: 1-888-797-2685

FAX: 614-308-5506

SCR Power Controls/Systems & Power Sup plies

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 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

George A. Sites Vice President

GAS/be

3563 Interchange R oad Co lumbus, OH 43204- 1400 USA Telephone: 614-308-5500 1-888-P WR-C N TL FAX : 614-308- 5506

REVISION PAGE

Page Change Revision Date

Various 1 Added DIP Switch information 8/00 31 2 Added EMC to CE Declaration 11/00

NOTE: ALL SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE.

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.............................................................................................................3

1-7 Diagnostic Indicators ...........................................................................................3

Section 2 - INSTALLATION

2-1 Mounting.............................................................................................................4

2-2 Line/Load Power Wiring......................................................................................4

2-3 Fan and Thermostat Wiring................................................................................19

2-4 Input Line Voltage Changes...............................................................................21

2-5 Safety Issues 21

Section 3 - COMM AND S IGNAL CALIBRATION AND WIRING

3-1 Zero and Span Adjustments................................................................................23

3-2 Command Indicator............................................................................................23

3-3 Isolated and Non-Isolated Inputs........................................................................23

3-4 Remote Manual Control.....................................................................................24

3-5 Process Command Signal...................................................................................25

3-6 Auto/Manual Control.........................................................................................25

3-7 ON/OFF Control................................................................................................26

3-8 Shutdown (Disable)............................................................................................27

Section 4 - MAINTENANCE

4-1 Environmental Concerns ....................................................................................28

4-2 Line/Load Power Connections ...........................................................................28

4-3 St atic Precautions when Servicing......................................................................28

4-4 Troubleshooting Typical Symptoms...................................................................28

Section 5 - SERVICE AND PARTS

5-1 Customer Service...............................................................................................30

5-2 Spare Parts.........................................................................................................30

5-3 Warranty............................................................................................................30

TABLES and ILLUSTRATIONS

TABLES

Table Title Page

1 Specifications.............................................................................................................2

2 Lug Size/Torque Information ....................................................................................4

3 Fan Power Requirements .........................................................................................20

4 Troubleshooting Zero Fired SCR Power Controllers .............................................. 29

ILLUSTRATIONS

Figure Title Page

1 Line/Load Power Wiring – ZF1..................................................................................5

2 Line/Load Power Wiring – ZF2..................................................................................5

3 Line/Load Power Wiring – ZF3..................................................................................6

4 Outline and Mounting – ZF1 60 and 90 through 225A...............................................7

5 Outline and Mounting – ZF1 350 and 500A...............................................................8

6 Outline and Mounting – ZF1 650A.............................................................................9

7 Outline and Mounting – ZF1 800 through 1200A.....................................................10

8 Outline and Mounting – ZF2 60 and 90 through 225A.............................................11

9 Outline and Mounting – ZF2 350 and 500A.............................................................12

10 Outline and Mounting – ZF2 650A...........................................................................13

11 Outline and Mounting – ZF2 800 through 1200A.....................................................14

12 Outline and Mounting – ZF3 60 and 90 through 225A.............................................15

13 Outline and Mounting – ZF3 350 and 500A.............................................................16

14 Outline and Mounting – ZF3 650A...........................................................................17

15 Outline and Mounting – ZF3 800 through 1200A.....................................................18

16 Fan & Thermostat Terminals....................................................................................19

17 Remote Manual Control...........................................................................................24

18 Auto/Manual Control...............................................................................................25

19 ON/OFF Control......................................................................................................26

20 Firing Circuit Terminals & DIP Switches..................................................................27

iii

Section 1 - DESCRIPTION

1-1 MODELS COVERED

This m an ual covers the ZF 1, ZF2 and Z F3 m odels rated 60 and 90 through 1200 am p ere s and options.

1-2 GENERAL DESCRIPTION

The ZF1 i s a s ingle-phase, zero-fired (ZF) SCR Power Control. The ZF 2 is three-phase 2-leg/4 SCR control and the ZF 3 is a three-phase, 3-leg/6 SCR Power Controller. Each o f th es e w ill op er a te o n vo lt ag es up t o 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 Contro ls utilize a variablet ime - b a s e that he lps ma intain c on s ta n t p ow e r to the loa d . T h is va ria b le - time- b a s e a ls o helps mi ni m ize tem perature overshoot, temperature fluctuations an d he l ps e xte nd th e l oad element’s life due to reduced thermal sh ock. 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 assem bly 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.

1-3 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 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 mech ani cal contactors and mercury relay s on drye rs, kil ns, ovens, env i ron m en tal ch am b e rs, ex tru der s, molding equipment, and most o ther 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.

1-4 SPECIFICATIONS

Refer to Table 1 for specifications on HDR’s Zero-Fired SCR Power Controls.

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, 575VAC, 50/60 Hz.

CURRENT RATINGS - 60, 90, 120, 180, 225, 350, 500, 650, 800, 1000, 1200 A. COMMAND SIGNAL - 4 to 20ma, 0 to 5VDC/0 to10VDC, manual control. ISOLATION - 2500Vrms from line/load to command signal,

500Vrms to ground.

LINEARITY - Outp ut Power is lin ea r to comman d s ignal (fixe d load). VOLTAGE REG. - +1% for +10% line voltage change. SCR PROTECTION - Curr ent surge, semi-conductor fuses; tr a nsient

voltage, metal oxide varistor (MOV) and R-C snubber

ADJUSTMENTS - Zero and Span, multi-turn DIAG. INDICATORS - Cont ro l powe r, command s ignal, blow n fu s e. AMBIENT TEM P. - Operating 0 - 50 °C, Storage -10 - 70 °C AGENCY APPROVALS - UL, cUL Listed & CE Compliant

1-5 OPTIONS

Available ZF1 options:

Over-temperature t hermostats are available as normally open (NO) or normally closed (NC). Thermostats are included on 90 through 1200 am pere uni ts as sta nd ard e quipmen t, specif y NO or NC. Either normall y open or normall y cl osed thermostats are avail able as an option on units rated 60 amperes, include NO or NC in your part number when specifying.

Mechanical L ine/Load l ugs are standard equipmen t on the 60 through 225 am pere rated units. They are avai lab l e for uni ts rated 350 through 1200 amperes as an option. Include LG in your part number when specifying.

The following options are available for t he ZF2 and ZF3 models:

Over-temperature t hermostats are available as normally open (NO) or normally closed (NC). Thermostats are standard equipment on uni ts rated 90 through 1200 amperes but needs to specified as NO or NC. If not specified, NO will be suppli ed. Both are availa bl e as an option on 60 ampere rated units but must be specified.

Mechani cal Li ne/Load lugs are avai lab le as an option on uni ts rated 350 to 1200 amperes and are specified b y addi n g L G to the Power Control’s model number. Mech anical l ugs are standard on units rated 60 ampere but must be specified NO or NC – normall y open will be s upplied if not specified.

An Unb alan ced Load alarm (UB) is avai l abl e as an option. Add UB to the model num ber when ordering a ZF2 or ZF3.

A Shorted SCR Failure al arm (SF) i s avai lab le as an option. Add SF to the mod el n umber when ordering.

1-6 OPERATION

HDR’s Zero-Fired SCR Power Controls control power by the switching action of two SCRs connected in a back to back configuration i n each controlled ph ase. The gatin g 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 P ower Contro ls t ur n the two S CRs in each phase on alternately as the incoming power passes through t he 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 cyc les) is minimize d for any c omman d sig nal leve l. Th is help s ensu re lo ad p owe r as cons ta n t a s p os s ib le w hile minimiz in g te mpe r a tur e ov e r s h oot, te mp e ra tu re flu c tu ations and helps extend heater element life by avoiding thermal shock and mechanical stress.

1-7 DIAGNOSTIC INDICATORS

Light Emitting Diodes diagnostic indicators (LE Ds) are provided for aid in start- up or mai n tenance. A Control Power On indi cator (Red) ligh ts when the power controll er h as 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 sem i conductor fuse and lights when t he corresp onding fuse blows.

Section 2 - INSTALLATION

2-1 MOUNTING

Prior t o mounting, verify the voltage and current rat ing of the SCR Power Contro l, 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 li ne/l oad termi nal s to the top so that air fl ow is upward through the heat sin k fi ns. Ensure that air flow is unrestricted. Keep in mind that high current units require large input/output cable. Allow plenty of room.

2-2 LINE/LOAD POWER WIRING

Connect the line/load using appropriately sized and insul ated wi re/cable per NEC based on the voltage and current rating of the Power Control. Cabl e lugs are provided on uni ts rated 60 through 225A, ratings above 225A have bus bar connections or optional mechanical lugs. Refer to T able 2 for lug sizes and torque information.

NOTE: U.L. requires 75°C rated wire (minimum) for all p owe r connections.

Model Size Wire/Cable Torque

60A (1) 8 to 0 AWG 45 in. Lbs. 90A (1) 8 to 0 AWG 45 in. Lbs. 120A (1) 8 to 0 AWG 45 in. Lbs. 180A (1) 6 to 250 MCM 250 in. Lbs. 225A (1) 6 to 250 MCM 250 in. Lbs.

Branch circuit overcurrent protection is required to be provided in accordance with the national and/or local code of the inspecting aut hor it y o r equivalent.

Lug Size/Torque Information – 60 to 225 ampere

WARNING

Table 2

Figure 1 - LINE/LOAD POWER WIRING ZF1 MODELS

Figure 2 – LINE/LOAD POWER WIRING ZF2 MODELS

Figure 3 – LINE/LOAD POWER WIRING ZF3 MODELS

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