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Ametek ZF2 SCR Series, Instruction, Operation And Maintenance Manual

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SCR POWER CONTROLLER  

 

Instruction, Operation and  
Maintenance Manual 

 
 

Number: 9100040 
Revision 3 

 
 

 

 
 

 
 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 

530 Lakeview Plaza Blvd, Ste C  

Worthington, Ohio, USA 43085 

Tol l  F re e :   1 -8 8 8- PW R -C NTL  (7 97 -2 6 8 5 )  

Ph one :  61 4 -3 0 8 -5 50 0  

Fa x :  61 4 -3 0 8 -5 50 6  

We b: 

w w w.hd rpow e r.c o m

 

ZF2/ZF3 SCR Series 

 

60-1200 Amperes 
Two/Three-phase 

Zero-fired

 

 

Summary of Contents for ZF2 SCR Series

Page 1: ...tenance Manual Number 9100040 Revision 3 530 Lakeview Plaza Blvd Ste C Worthington Ohio USA 43085 Toll Free 1 888 PWR CNTL 797 2685 Phone 614 308 5500 Fax 614 308 5506 Web www hdrpower com ZF2 ZF3 SCR...

Page 2: ...st you please call Ametek HDR Power Systems main office at 614 308 5500 Revision 1 September 2014 Initial Release Revision 2 July 2015 Revised Address Revision 3 August 2022 General Revision 2015 by A...

Page 3: ...7 Voltage Changeover 9 3 8 Options 10 CHAPTER 4 OPERATION 11 4 1 General 11 4 2 Front Panel Indicators 11 4 3 Command Input Control 11 4 4 Remote Manual Control with a Potentiometer 12 4 5 Auto Manual...

Page 4: ...4 Drawing List 31 CHAPTER 9 WARRANTY POLICY 32 9 1 Warranty 32 9 2 In house Repair Services 32 APPENDIX 34 Appendix A ZF2 System Schematic 34 Appendix B ZF3 System Schematic 35 Appendix C ZF2 60 225 A...

Page 5: ...emote Potentiometer 13 Figure 4 5 On Off Control 14 Figure 4 6 Shutdown Control 14 Figure 4 7 Unbalance Alarm Board 16 Figure 4 8 Shorted SCR Alarm Board 16 Figure 4 9 Unbalance Block Diagram 17 Figur...

Page 6: ...Table of Contents ZF2 ZF3 SCR Power Controller iv Ametek HDR Power Systems Rev 3...

Page 7: ...nect or circuit breaker with this Power Controller is required to ensure the safety of operating personnel CAUTION HAZARDOUS VOLTAGES exist at the Power Controller Heat Sinks and at the Load AT ALL TI...

Page 8: ...Safety Instructions ZF2 ZF3 SCR Power Controller 2 Ametek HDR Power Systems Rev 3...

Page 9: ...liminated Zero Fired controllers are versatile enough to be used in place of mechanical contactors and mercury relays on dryers kilns ovens environmental chambers extruders and most other applications...

Page 10: ...each SCR pair all SCRs have PIV rating of 1 400 V Three phase voltage imbalance 5 maximum from leg to leg SCCR Rating 100kA Miscellaneous Zero firing timebase Variable see 6 3 Controls ZERO and SPAN...

Page 11: ...ystems 5 If you will be using temperature process controller specify its output e g 4 20 mA 0 10 Vdc 2 10 Vdc etc with your order NOTE The ZF2 ZF3 should be tested or operated with an adequate load si...

Page 12: ...s LEDs are provided to give a visual indication of the board s operation On models rated from 60 through 225 amperes the CTs are mounted in the controller and on models rated from 350 amperes and high...

Page 13: ...sitive That is three phase input power can be connected in any sequence to terminals L1 L2 and L3 and will not cause an out of phase condition The fuses included are NOT meant for over current protect...

Page 14: ...Fan and Thermostat Connections 3 5 Command Signal Input HDR s Zero Fired SCR Power Controllers have the capability of having either an isolated current or non isolated voltage Command Signal input The...

Page 15: ...r On occasion customers may wish to operate a ZF2 ZF3 SCR Power Controller on line voltages other than what was specified when originally ordered The ZF2 ZF3 may be changed to accept a wide range of l...

Page 16: ...a label or tag noting that ZF2 ZF3 has been modified for line voltage other than what it was specified for This may prevent accidental use on an incorrect line voltage in the future 3 8 Options UB Op...

Page 17: ...Signal Indicator The Command Signal Indicator is a green Light Emitting Diode LED located on the front cover of the unit The brilliance of this LED will change with a current Command Signal The brilli...

Page 18: ...e test equipment The ZF2 ZF3 is now ready for automatic operation 4 4 Remote Manual Control with a Potentiometer Some applications only require a manual control input and not a closed loop input from...

Page 19: ...connect the test equipment 4 5 Auto Manual Control with a Controller and Remote Potentiometer On closed loop processes it may be desirable to be able to operate the unit manually The SCR Power Control...

Page 20: ...s shown in figure 4 5 A closed contact will turn on enable the ZF2 ZF3 Figure 4 5 On Off Control Calibrate the system by performing the steps in 4 3 Note that zero power demand is accomplished by open...

Page 21: ...hree phase currents are above the alarm setpoint the amber LED indicates that the line currents are insufficient to determine a load failure and the red LED indicates the alarm condition Each LED is l...

Page 22: ...en the SCRs are not shorted If an SCR shorts the respective green LED will go out and the red alarm LED will light and the Form C relay will energize The relay output is on terminals 81 N O 82 Common...

Page 23: ...ZF2 ZF3 SCR Power Controller Operation Rev 3 Ametek HDR Power Systems 17 Figure 4 9 Unbalance Block Diagram...

Page 24: ...Operation ZF2 ZF3 SCR Power Controller 18 Ametek HDR Power Systems Rev 3...

Page 25: ...pedances the output currents will have a 5 unbalance This factor alone is one of the most significant when one considers how many heating elements to monitor with one unbalance alarm circuit The line...

Page 26: ...e DIP switches Only adjust these potentiometers if you are measuring the test points and trimming out current errors under controlled conditions If you are only using 3 or 4 heating elements per leg t...

Page 27: ...portional low level voltage or milliampere output signal The firing control circuit may also be turned on and off by an external switch or relay contacts Chapter 4 discusses some external control meth...

Page 28: ...is exactly equal to the frequency of the input signal For each cycle of input there is one cycle of oscillator output By this method the ZF2 ZF3 s output will be held at 50 Hz or 60 Hz depending on co...

Page 29: ...caused by one or more of the following an environmental problem faulty input power or load connections and the ZF2 ZF3 itself These possible causes should be investigated as described in Chapters 7 4...

Page 30: ...irt for proper heat transfer and free of obstructions which could prevent proper airflow Contamination The unit should be periodically cleaned of all dust and dirt However certain kinds of dust or par...

Page 31: ...s indicated in any of these checks replace it On units rated at 225 A and below Disconnect power and check the front to back SCR pairs by measuring resistance between terminals L1 of the SCR and X1 On...

Page 32: ...Troubleshooting ZF2 ZF3 SCR Power Controller 26 Ametek HDR Power Systems Rev 3...

Page 33: ...arrange for service at your site or by shipment to Ametek HDR Power System as you request We will make every possible attempt to support your emergency on site needs regardless of how contacted 8 2 Sp...

Page 34: ...0 6791114 2 3 1 2 2 120 Ampere Units Fan axial 115 Vac 110 CFM Fuse 150 A 700 V PCB Assy ZF2 PCB Assy DVDT SCR dual pkg 90 A 1400 V 4520001 7515170I 2099158 2099000 6791114 2 3 1 2 2 180 Ampere Units...

Page 35: ...2 1200 Ampere Units Fan axial 115 Vac 350 CFM Fuse 1600 A 700 V Lug Kit 2 3 Phase 1200 A PCB Assy ZF2 SCR 2800 A 1400 V PCB Assy DVDT 4520002 7500128 2710213 2099158 5028214 2072000 3 3 1 1 4 2 Table...

Page 36: ...099162 5080114 2071000 3 3 1 1 6 3 650 Ampere Units Fan axial 115 Vac 350 CFM Fuse 800 A 700 V Lug Kit 2 3 Phase 650 A PCB Assy PF3 SCR 1500 A 1400 V PCB Assy DVDT 4520002 7500125 2710210 2099162 5015...

Page 37: ...model Appendix provides simplified drawings in the order of their appearance Drawings may also be downloaded from www hdrpower com Table 8 3 ZF2 ZF3 Drawing List Drawing Title Drawing No Schematic ZF2...

Page 38: ...Y STRICT LIABILITY OR OTHERWISE IN NO EVENT WILL AMETEK HDR BE LIABLE FOR INCIDENT OR CONSEQUENTIAL DAMAGES NOR IN ANY EVENT SHALL HDR S LIABILITY EXCEED THE UNIT PRICE OF ANY DEFECTIVE PRODUCT OR PAR...

Page 39: ...Power Systems 33 9 3 Field Service Repairs Repairs may be performed at your location Please contact Ametek HDR Power Systems at 614 308 5500 to discuss terms and conditions to get the current service...

Page 40: ...Appendix ZF2 ZF3 SCR Power Controller 34 Ametek HDR Power Systems Rev 3 APPENDIX Appendix A ZF2 System Schematic Note CT s are optional Fans and Thermostats may not be included in certain models...

Page 41: ...ZF2 ZF3 SCR Power Controller Appendix Rev 3 Ametek HDR Power Systems 35 Appendix B ZF3 System Schematic Note CT s are optional Fans and Thermostats may not be included in certain models...

Page 42: ...Appendix ZF2 ZF3 SCR Power Controller 36 Ametek HDR Power Systems Rev 3 Appendix C ZF2 60 225 A Outline R...

Page 43: ...ZF2 ZF3 SCR Power Controller Appendix Rev 3 Ametek HDR Power Systems 37 Appendix D ZF2 350 500 A Outline R...

Page 44: ...Appendix ZF2 ZF3 SCR Power Controller 38 Ametek HDR Power Systems Rev 3 Appendix E ZF2 650 A Outline R...

Page 45: ...ZF2 ZF3 SCR Power Controller Appendix Rev 3 Ametek HDR Power Systems 39 Appendix F ZF2 800 1200 A Outline R...

Page 46: ...Appendix ZF2 ZF3 SCR Power Controller 40 Ametek HDR Power Systems Rev 3 Appendix G ZF3 60 225 A Outline R...

Page 47: ...ZF2 ZF3 SCR Power Controller Appendix Rev 3 Ametek HDR Power Systems 41 Appendix H ZF3 350 500 A Outline R...

Page 48: ...Appendix ZF2 ZF3 SCR Power Controller 42 Ametek HDR Power Systems Rev 3 Appendix I ZF3 650 A Outline...

Page 49: ...ZF2 ZF3 SCR Power Controller Appendix Rev 3 Ametek HDR Power Systems 43 Appendix J ZF3 800 1200 A Outline R...

Page 50: ...aration 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...

Page 51: ...Notes...

Page 52: ...503 Lakeview Plaza Blvd Ste C Worthington Ohio 43085 USA...

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