Ametek PF1 SCR Series Manual de operación y mantenimiento

SCR POWER CONTROLLER

Instruction, Operation and

Maintenance Manual

Number: 9100032

Revision 3

530 Lakeview Plaza Blvd, Ste C

Worthington, Ohio, USA 43085

Toll F re e : 1 - 8 88- PWR- C NTL (7 9 7 -26 85)

Ph o n e: 61 4 -3 0 8-550 0

Fa x : 614 - 3 08 - 5506

Web: w w w .hd rpow e r. c o m

PF1 SCR Series

60-1200 Amperes

Single-phase

Phase-fired

This manual applies to all Model PF1 SCR Power Controls. Former PF1/PF3 manual – 9100014 has been

replaced with this manual.

For the support representative nearest 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

 2022 by Ametek HDR Power Systems. No portion of this document may be reproduced either mechanically or electronically without the

prior consent of Ametek HDR Power Systems.

PF1 SCR Power Controller Table of Contents

Rev 3 Ametek HDR Power Systems i

TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS ............................................................................................................. 1

CHAPTER 1 - DESCRIPTION .............................................................................................................................. 3

1.1 General Description 3

1.2 Application 3

1.3 Operation 3

1.4 Specification 3

CHAPTER 2 - OPTIONS ...................................................................................................................................... 5

2.1 General 5

2.2 Option OC (Single-Phase Overcurrent Trip) 5

2.3 Option CL/OC (Current Limit/Overcurrent Trip) 5

2.4 Option CR/OC (Current Regulation/Overcurrent Trip) 5

2.5 Option PR (Power Regulation with Current Limit) 6

2.6 Option VIPR (Voltage, Power, Resistance Regulation) 6

2.7 Option LG (Lug Kit) 6

2.8 Option ER (Extended Ramp) 6

2.9 Additional Options 6

CHAPTER 3 - INSTALLATION ............................................................................................................................ 7

3.1 Mounting the PF1 7

3.2 Input/Output Wiring 7

3.3 Fan Wiring (applicable to models rated 90 A and higher) 7

3.4 Wiring Overtemperature Contacts 8

3.5 Command Signal Input 8

3.6 Determining Line Frequency 9

3.7 Voltage Changeover 9

3.8 Options 10

CHAPTER 4 - OPERATION ............................................................................................................................... 12

4.1 General 12

4.2 Front Panel Indicators 12

4.3 Command Input Control 12

4.4 Remote Manual Control with a Potentiometer 13

4.5 Auto/Manual Control with a Controller and Remote Potentiometer 14

4.6 On/Off Control 15

4.7 Shutdown 16

CHAPTER 5 – OPTIONS SETUP ...................................................................................................................... 17

5.1 Option OC (Overcurrent Trip) 17

5.2 Option CL/OC (Current Limit/Over Current Trip) 17

5.3 Option CR/OC (Current Regulation/Over Current Trip) 18

5.4 Option PR 18

5.5 Option VIPR 18

CHAPTER 6 - THEORY...................................................................................................................................... 21

6.1 Functional Description 21

6.2 Overview of the PF1 21

6.3 Digital Firing Control Circuit 21

6.4 Pulse-Train Firing 21

6.5 Phase-Lock Loop 21

6.6 SPAN and ZERO Controls 22

6.7 Voltage-Squared Feedback 22

Table of Contents PF1 SCR Power Controller

ii Ametek HDR Power Systems Rev 3

6.8 Shut-down 22

6.9 Soft-Start Circuit 22

CHAPTER 7 – TROUBLESHOOTING ............................................................................................................... 23

7.1 Customer-Service Program 23

7.2 Troubleshooting Typical Symptoms 23

7.3 Static Precautions when Servicing 23

7.4 Environmental Problems 24

7.5 Input Power and Load Connections 24

7.6 Correcting Troubles in the PF1 Itself 25

CHAPTER 8 - SERVICE ..................................................................................................................................... 26

8.1 Communication Procedures 26

8.2 Spare Parts Orders – Routine or Emergency 26

8.3 Spare Parts List 27

8.4 Drawing List 28

CHAPTER 9 – WARRANTY POLICY ................................................................................................................ 29

9.1 Warranty 29

9.2 In-house Repair Services 29

APPENDIX .......................................................................................................................................................... 31

Appendix A – System Schematic 31

Appendix B – 60-225 A Outline 32

Appendix C – 350-500 A Outline 33

Appendix D – 650 A Outline 34

Appendix E – 800-1200 A Outline 35

Appendix F – Declaration of Conformity 36

PF1 SCR Power Controller Table of Contents

Rev 3 Ametek HDR Power Systems iii

TABLE OF CONTENTS

Par. Title Page

ILLUSTRATIONS

Figure 3.1 Fan and Thermostat Connections .................................................................................................. 8

Figure 3.2 Isolated/Non-Isolated Switches ...................................................................................................... 9

Figure 3.3 T1 Transformer Connections .......................................................................................................... 9

Figure 3.4 Typical PF1 Line and Load Connections ..................................................................................... 11

Figure 4.1 Control Panel .................................................................................................................................. 12

Figure 4.2 Process Controller Input Connections ........................................................................................ 13

Figure 4.3 Remote Control with a Potentiometer ......................................................................................... 14

Figure 4.4 Auto/Man Control with Controller and Remote Potentiometer ................................................. 15

Figure 4.5 On/Off Control ................................................................................................................................ 15

Figure 4.6 Shutdown Control .......................................................................................................................... 16

Figure 5.1 Current Limit/Trip Board ............................................................................................................... 17

Figure 5.2 VIPR Board ..................................................................................................................................... 19

Figure 6.1 AC Switch and SCR On-time ......................................................................................................... 21

TABLES

Table 1.1 PF1 Model Number Breakdown........................................................................................................ 3

Table 1.2 General Specifications of PF1 Models ............................................................................................ 4

Table 3.1 Wire Size Information ........................................................................................................................ 7

Table 5.1 VIPR Regulation Switch Settings ................................................................................................... 19

Table 7.1 Troubleshooting Chart (Symptoms and Solutions) ..................................................................... 25

Table 7.2 Torque Specifications ..................................................................................................................... 25

Table 8.1 PF1 Spare Parts List ........................................................................................................................ 27

Table 8.2 PF1 Drawing List ............................................................................................................................. 28

Table of Contents PF1 SCR Power Controller

iv Ametek HDR Power Systems Rev 3

PF1 SCR Power Controller Safety Instructions

Rev 3 Ametek HDR Power Systems 1

SAVE THESE INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS

WARNING

Observe all warnings and cautions in this manual. Failure to do so may result in serious injury or death.

Refer all service to properly trained and qualified service personnel. Never work alone.

Lethal voltages exist on exposed heat sinks even if the power controller is turned off. Remove power and lock

out power before attempting any service.

This manual contains important safety instructions that must be followed during the installation and

maintenance of the SCR Power controller. Read this manual thoroughly before attempting to operate this

Power controller.

An appropriate branch circuit fused disconnect 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 TIMES, when

input voltage is connected. This condition exists even when the Power Controller is set to deliver zero output.

Printed circuit boards contain sensitive components that can be damaged by electrostatic discharge (ESD).

Observe precautions for handling electrostatic sensitive devices. Reference Maintenance and Troubleshooting

(Chapter 7) of this manual for details

In case of fire, use a dry chemical fire extinguisher to put out the fire. Using a liquid fire extinguisher may

cause electric shock.

The SCR Power Controller makes use of components dangerous for the environment (electronic printed circuit

boards, electronic components). The components removed must be taken to specialized collection and

disposal centers.

E151547

100kA SCCR

IEC 947-5-1

Safety Instructions PF1 SCR Power Controller

2 Ametek HDR Power Systems Rev 3

PF1 SCR Power Controller Description

Rev 3 Ametek HDR Power Systems 3

CHAPTER 1 - Description

1.1 General Description

The PF1 is a Single-phase, phase-fired power controller, and can operate with a wide variety of input

signals and line voltages up to 575 Vac and currents ranging from 60 through 1200 amperes. The

PF1’s output voltage is proportional to its input signal. The PF1 features pulse-train firing which

provides high immunity to possible SCR firing disturbances, and phase-lock loop circuitry which

ensures line frequency synchronization. Other features are input isolation from ground, soft-start, and

automatic restart circuitry. Terminals are provided to permit connection of a variety of external control

methods. A more detailed description of the features mentioned above is provided in Chapter 6 of this

manual.

1.2 Application

Phase-Fired SCR Power Controllers provide infinitely variable firing angles for precise control of

single-phase power to resistive or inductive loads. This precise control is essential for transformer

coupled loads or loads with great resistance changes due to temperature or start-up. Phase-Fired

units may also be used on straight resistive loads as well, but the lower power factor and higher

harmonics may present a problem to other equipment mounted nearby. A zero fired model would be a

better choice.

1.3 Operation

The PF1 accomplishes power control by the switching action of a pair of inverse-parallel power SCRs.

The switching, or gating, of the SCRs is controlled by a digital firing control circuit synchronized “in

phase” with line frequency (either 50 or 60 Hz). A soft-start (approximately a 12 cycle ramp) feature is

standard that allows the Power Controller to fire into the primary of a transformer or to control power to

heating elements which have a large resistance change during start-up. The output may be adjusted

by the on-board multi-turn potentiometers or by a voltage or current signal from a process controller.

ZERO and SPAN controls allow the user to calibrate the SCR unit's output to the process command

signal. Terminals are available for connection of a remote manual potentiometer.

1.4 Specification

Specifications for the PF1 SCR power controller are given in Tables 1.1 and 1.2.

Table 1.1 PF1 Model Number Breakdown

PF1 – 480 – 225 – CR – UB – 01

NOTE: N.O. Thermostat is included in current ratings above 60 A.

120 Vac - 120

240 Vac - 240

400 Vac - 400

480 Vac - 480

575 Vac -

575

60 A rms - 60

90 A rms - 90

120 A rms - 120

180 A rms - 180

225 A rms - 225

350 A rms - 350

500 A rms - 500

650 A rms - 650

800 A rms - 800

1000 A rms - 1000

1200 A rms

1200

N.O. Thermostat - NO

N.C. Thermostat - NC

RMS Current Limit/OC - CL

RMS Current Reg/OC - CR

Over Current Trip - OC

True Power Reg/CL - PR

Volt/Cur/Pwr/ResReg - VIPR

Extended Ramp - ER

Lug Kit (>225 A) - LG

Can have multiple selections

4-20 mA - 01

0-10 Vdc - 02

0-5 Vdc - 03

Auto/Man - 04

Manual Pot input - 05

Others

Description PF1 SCR Power Controller

4 Ametek HDR Power Systems Rev 3

Table 1.2 General Specifications of PF1 Models

Input line voltage: * 120, 240, 400, 480, or 575 Vac,

+10%, -15% , Single-phase

Line frequency: * 50 or 60 Hz

Current rating:

As indicated by model number (refer to Table 1.1)

Thermostat contact rating: 120 Vac, 5 A; resistive

Input Signal:

Non-isolated

Isolated

0 to 1.5 V (min); 0 to 10 V (max)

0 to 6 mA (min); 0 to 20 mA (max)

Control methods: 1. Potentiometer, 5 kΩ, 1/2 watt (Customer-supplied).

2. Dry contact closure (customer-supplied).

3. Temperature or process controller

Control signal input impedance:

Non-isolated input

Isolated input

1500 Ω

500 Ω

Control signal isolation:

From SCRs 2,500 Vac

From ac power input lines 2,500 Vac

From chassis 500 Vac

Power output:

Voltage regulation Voltage Squared

Power output linearity versus

control signals input

+2% (Non-isolated)

+5% (Isolated)

Power SCRs protection:

Current surge Subcycle I² T semiconductor fuse.

Transient voltage spikes (dv/dt)

SCCR Rating

Metal Oxide Varistor (MOV) and R-C snubber across each SCR pair; all

SCRs have PIV rating of 1,400 V.

100kA

Miscellaneous:

Phase-firing timebase 0º to 180º conduction per SCR

Controls: ZERO and SPAN potentiometers; 10-turn, screwdriver-adjustable.

Approvals UL/cUL (E151547), CE

cooling power (as applicable):

For 90 A through 500 A units 0.21 amperes, 25 VA (50 Hz)

0.19 amperes, 23 VA (60 Hz)

For 650 A through 1200 A units

1.2 amperes, 144 VA (50 Hz)

1.4 amperes, 168 VA (60 Hz)

Ambient Tem

erature range:

Environment 32 ºF to 122 ºF ( 0 ºC to 50 ºC) surrounding air

Pollution degree 2

Overvoltage Category III

Storage 14 ºF to 158 ºF ( -10 ºC to 70 ºC)

Weight per unit: Current Rating

60 through 225 A

350, 500 A

650 A

800, 1000, 1200 A

lbs

10.9

12.3

32.2

Outline and mounting: See appropriate drawing in Appendix

* Specify with order

** 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 PF1 should be tested or operated with an adequate load since an open output will have line

voltage at the load connections.

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