Ametek ZF2 SCR Series Manual de operación y mantenimiento

SCR POWER CONTROLLER

Instruction, Operation and

Maintenance Manual

Number: 9100040

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

ZF2/ZF3 SCR Series

60-1200 Amperes

Two/Three-phase

Zero-fired

This manual applies to all Model ZF2/ZF3 SCR Power Controls. Former ZF2/ZF3 manual – 9100029 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

 2015 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.

ZF2/ZF3 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 ...................................................................................................................................... 6

2.1 Option UB (Unbalance Alarm) 6

2.2 Option SF (Shorted SCR Failure Alarm) 6

2.3 Option LG (Lug Kit) 6

2.4 Additional Options 6

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

3.1 Mounting the ZF2/ZF3 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 ............................................................................................................................... 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 Control with a Controller and Remote Potentiometer 13

4.6 On/Off Control 14

4.7 Shutdown 14

4.8 Unbalance Alarm 15

4.9 Shorted SCR Alarm 16

CHAPTER 5 – OPTIONS SETUP ...................................................................................................................... 19

5.1 Option UB (Unbalance Alarm) 19

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

6.1 Functional Description 21

6.2 Digital Firing Control Circuit 21

6.3 Variable-Time Base 21

6.4 Pulse-Train Firing 22

6.5 Phase-Lock Loop 22

6.6 SPAN and ZERO Controls 22

6.7 Voltage-Squared Feedback 22

6.8 Shut-down 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

Table of Contents ZF2/ZF3 SCR Power Controller

ii Ametek HDR Power Systems Rev 3

7.5 Input Power and Load Connections 24

7.6 Correcting Troubles in the ZF2/ZF3 Itself 25

CHAPTER 8 - SERVICE ..................................................................................................................................... 27

8.1 Communication Procedures 27

8.2 Spare Parts Orders – Routine or Emergency 27

8.3 Spare Parts List 28

8.4 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 Outline 36

Appendix D – ZF2 350-500 A Outline 37

Appendix E – ZF2 650 A Outline 38

Appendix F – ZF2 800-1200 A Outline 39

Appendix G – ZF3 60-225 A Outline 40

Appendix H – ZF3 350-500 A Outline 41

Appendix I – ZF3 650 A Outline 42

Appendix J – ZF3 800-1200 A Outline 43

Appendix K – Declaration of Conformity 44

ZF2/ZF3 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 ZF2/ZF3 Line and Load Connections ............................................................................. 10

Figure 4.1 Control Panel .................................................................................................................................. 11

Figure 4.2 Process Controller Input Connections ........................................................................................ 12

Figure 4.3 Remote Control with a Potentiometer ......................................................................................... 13

Figure 4.4 Auto/Man Control with Controller and Remote 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

Figure 6.1 AC Switch ....................................................................................................................................... 21

TABLES

Table 1.1 ZF2 and ZF3 Model Number Breakdown ......................................................................................... 3

Table 1.2 General Specifications of ZF2/ZF3 Models ..................................................................................... 4

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

Table 3.2 Transformer Voltage Wiring ........................................................................................................... 10

Table 5.1 Unbalance DIP Switch Settings...................................................................................................... 19

Table 6.1 Variable-Time-Base Relationship (Example) ................................................................................ 21

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

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

Table 8.1 ZF2 Spare Parts List ........................................................................................................................ 28

Table 8.2 ZF3 Spare Parts List ........................................................................................................................ 29

Table 8.3 ZF2/ZF3 Drawing List ...................................................................................................................... 31

Table of Contents ZF2/ZF3 SCR Power Controller

iv Ametek HDR Power Systems Rev 3

ZF2/ZF3 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 ZF2/ZF3 SCR Power Controller

2 Ametek HDR Power Systems Rev 3

ZF2/ZF3 SCR Power Controller Description

Rev 3 Ametek HDR Power Systems 3

CHAPTER 1 - Description

1.1 General Description

The ZF2 is three-phase 2-leg/4 zero-fired SCR control and the ZF3 is a three-phase, 3-leg/6 zero-fired

SCR Power Controller. Each of these 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 ZF2/ZF3’s output

voltage is proportional to its input signal. HDR’s zero-fired SCR Power Controls utilize a variable-time-

base that helps maintain constant power to the load. This variable-time-base also helps minimize

temperature overshoot, temperature fluctuations and helps extend the load element’s life due to

reduced thermal shock. The ZF2/ZF3 also 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.

1.2 Application

Zero-Fired SCR Power Controls provide control of 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 mechanical contactors and mercury relays on dryers, kilns, ovens, environmental

chambers, extruders, and most other applications where resistive heating elements are used. Normal

Zero-Fired SCR Power Controllers should never be used on inductive loads.

1.3 Operation

The ZF2/ZF3 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). 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 ZF2/ZF3 SCR power controller are given in Tables 1.1 and 1.2.

Table 1.1 ZF2 and ZF3 Model Number Breakdown

ZF2 (or ZF3) – 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

Unbalance Alarm - UB

Shorted SCR Alarm - SF

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 ZF2/ZF3 SCR Power Controller

4 Ametek HDR Power Systems Rev 3

Table 1.2 General Specifications of ZF2/ZF3 Models

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

+10%, -15% , Three-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:

Power output linearity versus

control signals input

+3%

Power SCRs protection:

Current surge Subcycle I² T semiconductor fuse.

Transient voltage spikes (dv/dt)

Metal Oxide Varistor (MOV) and R-C snubber across 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 potentiometers; 10-turn, screwdriver-adjustable.

Approvals UL/cUL (E151547), CE

Fan

cooling power (as applicable):

ZF2

ZF3

For 90 A through 225 A units 0.21 amperes, 50 VA (50 Hz)

0.19 amperes, 46 VA (60 Hz)

0.42 amperes, 50 VA (50 Hz)

0.38 amperes, 46 VA (60 Hz)

For 350 A through 500 A units 0.42 amperes, 76 VA (50 Hz)

0.46 amperes, 69 VA (60 Hz)

0.63 amperes, 76 VA (50 Hz)

0.57 amperes, 69 VA (60 Hz)

For 650 A through 1200 A units

2.8 amperes, 504 VA (50 Hz)

2.4 amperes, 432 VA (60 Hz)

4.2 amperes, 504 VA (50 Hz)

3.6 amperes, 432 VA (60 Hz)

Ambient Temperature 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

ZF2

ZF3

60 through 225 A

350, 500 A

650 A

800, 1000, 1200 A

31 lbs

41 lbs

87 lbs

180 lbs

14.1 kg

18.6kg

39.6 kg

47.6 kg

40 lbs

60 lbs

126 lbs

231 lbs

18.2 kg

27.3kg

57.3 kg

104.8 kg

Outline and mounting: See appropriate drawing in Appendix

* Specify with order

Este manual sirve para los siguientes modelos

Tabla de contenidos

Otros manuales de Controladores de Ametek

Ametek

Ametek DPA1 Series Instrucciones de funcionamiento

Ametek

Ametek 88740.01210 Manual de usuario

Ametek

Ametek ZF1 SSR Series Manual de operación y mantenimiento

Ametek

Ametek Dunkermotoren BGE 6060 A EC Manual de usuario

Ametek

Ametek Gemco 952CP Ram-Set Manual

Ametek

Ametek dunkenmotoren BGE 6060 A Manual de usuario

Ametek

Ametek PF1 SSR Series Manual de operación y mantenimiento

Ametek

Ametek PMT 40 Manual de usuario

Ametek

Ametek BrookField TC Series Manual de usuario

Ametek

Ametek Magnetrol Tuffy Manual de usuario

Ametek

Ametek ZF2 Series Manual de operación y mantenimiento

Ametek

Ametek Gemco 1996 Ram-Set Manual

Ametek

Ametek Princeton Applied Research PARSTAT 2273 Instrucciones de uso

Ametek

Ametek SHPF1 SCR Series Manual de operación y mantenimiento

Ametek

Ametek MP3 SCR DeviceNet Head Manual de usuario

Ametek

Ametek PF3 SCR Series Manual de operación y mantenimiento

Ametek

Ametek dunkermotoren ServoTube XTR 25 Manual de usuario

Ametek

Ametek SHZF2 SCR Series Manual de operación y mantenimiento

Ametek

Ametek PF1 SCR Series Manual de operación y mantenimiento

Ametek

Ametek dunkermotoren BGE 6010 A Manual de usuario

Ametek

Ametek SurgeX SX2200 Series Manual de usuario

Ametek

Ametek SCR2000 Manual de usuario

Ametek

Ametek SHPF3 Series Manual de operación y mantenimiento

Ametek

Ametek SCPF1 SSR Series Manual de operación y mantenimiento

Manuales populares de Controladores de otras marcas

Digiplex

Digiplex DGP-848 Instrucciones de funcionamiento

YASKAWA

YASKAWA SGM series Manual de usuario

Sinope

Sinope Calypso RM3500ZB Manual de usuario

Isimet

Isimet DLA Series Style 2 Manual de instalación

LSIS

LSIS sv-ip5a Manual de usuario

Rockwell Automation

Rockwell Automation 1769-L31 Manual de usuario

Airflow

Airflow Uno hab Manual de usuario

ABB

ABB ACS580-01 drives Manual de usuario

Panasonic

Panasonic GM1 Series Manual de usuario

Emerson

Emerson SW93 Manual de usuario

AutoAqua

AutoAqua Smart ATO micro SATO-120P Manual de usuario

Panasonic

Panasonic FP? Positioning Unit RTEX Manual de usuario

Samson

Samson Type 5824 Manual de servicio

Alpha IP

Alpha IP MIOB 21001 Manual de usuario

Siemens

Siemens OpenAir GMA 1 Series Manual de usuario

Surecom

Surecom SR-629 Manual de usuario

Fishman

Fishman TriplePlay Manual de usuario

Regulus

Regulus SRS1 T Manual de usuario