Control Concepts FUSION Series Manual de instrucciones
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COMPACT FUSION
INSTALLATION &
MAINTENANCE MANUAL
© Control Concepts Inc., 2013
www.ccipower.com 1-800-765-2799
Compact FUSION Installation ManualRevision 3.50.2
SCR POWER CONTROLLERS
CONTROL CONCEPTS, INC. 2 YEAR LIMITED WARRANTY
CONTROL CONCEPTS, INC. warrants that the products delivered will be as described in the sales order or contract.
CONTROL CONCEPTS, INC. warrants to the original user that CONTROL CONCEPTS, INC. products will be free from
defects in materials and workmanship for a period of two (2) years after the date CONTROL CONCEPTS, INC. ships
such products.
If any CONTROL CONCEPTS, INC. product is found to be defective in material or workmanship during the applicable
warranty period, CONTROL CONCEPTS, INC.’s entire liability, and purchasers sole and exclusive remedy, shall be the
repair or replacement of the defective product at CONTROL CONCEPTS, INC.’s election. CONTROL CONCEPTS,
INC. shall not be liable for any costs or expenses, whether direct or indirect, associated with the installation, removal or
re-installation of any defective product. All shipping and freight costs are the responsibility of the customer. CONTROL
CONCEPTS, INC.’s limited warranty shall not be effective or actionable unless there is compliance with all installation
and operating instructions furnished by CONTROL CONCEPTS, INC., or if the products have been modified or altered
without the written consent of CONTROL CONCEPTS, INC., or if such products have been subject to accident, misuse,
mishandling, tampering, negligence or improper maintenance. Any warranty claim must be submitted to CONTROL
CONCEPTS, INC. in writing within the stated warranty period.
CONTROL CONCEPTS, INC.’s limited warranty is made in lieu of, and CONTROL CONCEPTS, INC. disclaims all other
warranties, whether expressed or implied, including but not limited to any IMPLIED WARRANTY OF MERCHANTABILITY,
ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, any implied warranty arising out of a
course of dealing or of performance, custom or usage of trade.
CONTROL CONCEPTS, INC. SHALL NOT, UNDER ANY CIRCUMSTANCES BE LIABLE FOR ANY DIRECT,
INDIRECT, INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, LOSS
OF PROFITS, REVENUE OR BUSINESS) OR DAMAGE OR INJURY TO PERSONS OR PROPERTY IN ANY WAY
RELATED TO THE MANUFACTURE OR THE USE OF ITS PRODUCTS. The exclusion applies regardless of whether
such damages are sought based on breach of warranty, breach of contract, negligence, strict in tort, or any other legal
theory, even if CONTROL CONCEPTS, INC. has notice of the possibility of such damages.
By purchasing CONTROL CONCEPTS, INC.’s products, the purchaser agrees to the terms and conditions of this
limited warranty.
WARNING: The Control Concepts, Inc. power controllers use power thyristors to switch voltage to the connected
load. Line voltage must be assumed at the output terminals at all times, even when the control signal has been
removed and the load voltage appears to be off. It has been mandated by the National Electrical Code and the
Occupational Safety and Heath Act of 1970 that a physical disconnect be opened ahead of all remotely actuated
controls before performing any maintenance work on the controller or its connected load.
PROPRIETARY DATA
© Copyright 2010, Control Concepts, Inc. Chanhassen, MN 55317
The information and design disclosed herein are the property of Control Concepts, Inc. and may not be used,
reproduced or disclosed in any form except as granted in writing by:
CONTROL CONCEPTS, INC
18760 LAKE DRIVE EAST
CHANHASSEN, MN 55317
PHONE: (952) 474-6200
TOLL FREE: (800) 765-2799
FAX: (952) 474-6070
www.ccipower.com
© Control Concepts Inc., 2013
www.ccipower.com 1-800-765-2799
Compact FUSION Installation Manual Revision 3.50.2
TABLE OF CONTENTS
DECLARATION OF CONFORMITY....................................................................ii
CERTIFICATE OF COMPLIANCE .....................................................................iv
1. RECOMMENDED FUSING............................................................................ 1
2. INSTALLATION .............................................................................................. 2
2.1 Mounting Considerations...................................................................... 2
2.2 Mounting Dimensions for Single Module Controllers............................ 3
2.3 Mounting Dimensions for Two Module Controllers ............................... 4
2.4 Remote Display Kit ............................................................................... 5
2.4.1 Mounting Considerations ........................................................... 5
2.4.2 Mounting Instructions................................................................. 6
3. WIRING .......................................................................................................... 8
3.1 Torque Specifications............................................................................ 8
3.2 Universal Input Power........................................................................... 9
3.3 AC Cable Entry Heights / Wire Acceptance........................................ 10
3.4 Line / Load Connections..................................................................... 11
3.4.1 Single Phase............................................................................ 11
3.4.2 Single Phase, Two Zone.......................................................... 12
3.4.3 Single Phase, Three Zone ....................................................... 13
3.4.4 Single Phase, Four Zone ......................................................... 14
3.4.5 Single Phase with Pass-Through............................................. 15
3.4.6 Single Phase Two Zone with Pass-Through............................ 16
3.4.7 Three Phase - Two Leg............................................................ 17
3.4.8 Three Phase - Two Leg, with Pass-Through............................ 18
3.4.9 Three Phase Three Leg - Delta or Three Wire Wye ................ 19
3.4.10 Three Phase Three Leg - Inside Delta................................... 20
3.4.11 Three Phase, Three Leg - Four Wire Wye ............................. 21
3.5 Connectors ......................................................................................... 22
3.5.1 P1-12 Pin Command Connector.............................................. 22
3.5.2 External Feedback................................................................... 23
3.5.3 SYNC-GUARD™ ..................................................................... 23
3.5.4 P2 - 6 Pin Relay Connector ..................................................... 24
3.5.5 P3 - 10 Pin Auxiliary I/O Connector ......................................... 24
3.5.6 P4 - Remote Display Connector .............................................. 24
4. AUX I/O Card (Optional)............................................................................... 25
4.1 P3 - 10 Pin Aux I/O Connector............................................................ 25
APPENDIX A: Changing from Inside Delta to Delta or 3-Wire Wye Load ........ 26
APPENDIX B: Changing from 4 Wire Wye to Delta or 3-Wire Wye Load ........ 27
APPENDIX C: Fuse Replacement.................................................................... 28
i© Control Concepts Inc., 2013
www.ccipower.com 1-800-765-2799
Compact FUSION Manual Certications
Listed 3L32 - Industrial Control Equipment
100kA Short Circuit Current Rating
File Number E136219
EN60947-4-3
IP 20
See CE Declaration of Conformity
Part 15 Subpart B
Class A Device
See RoHS Certificate of Compliance
ii
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© Control Concepts Inc., 2013 Compact FUSION Manual Certications
FUSION CF Series SCR Power Controller
Control Concepts, Inc.
18760 Lake Drive East
Chanhassen, MN 55317 USA
Declares that the following product:
Designation: FUSION CF Series Power Controller
Model Numbers: Model CF followed by ZC, PA, followed by 1, 2 or 3, followed by 1 through 9 or A through E
followed by number or letter, may be followed by numbers and/or letters, may be followed
by numbers and/or letters, may be followed by numbers and/or letters.
Classification: Solid State Power Controller, Class I, Pollution Degree II
Rated Voltage: 24 - 600 Vac
Rated Frequency: 45 - 65 Hz
Meets the essential requirements of the following European Union Directive(s) using the relevant section(s) of the
normalized standards and related documents shown:
EN 60947-4-3: 2000 Low-voltage switchgear and controlgear
EMC Directive 2004/108/EC
-EN 61000-6-2: 2005
-EN61000-4-2: 1995 + Amendments A1:1998 + A2: 2001 ESD Immunity
-EN61000-4-3: 2006 Radiated Immunity
-EN61000-4-4: 2004 + Corrigendum 2004 EFT / Burst Immunity
-EN61000-4-5: 2006 Surge Immunity
-EN61000-4-6: 2007 Conducted Immunity
-EN61000-4-8: 1993 + Amendment A1: 2001 Magnetic Field Immunity
-EN61000-4-11 Second Edition: 2004 Voltage Dips & Interruptions
-EN 61000-6-4: 2007 Conducted & Radiated Emissions
Note 1: All power terminals must be populated as to keep the controller touch safe to comply with EN 60947-4-3.
Note 2: Controller must be mounted in a shielded enclosure to comply with EMC Directive 2004/108/EC.
Note 3: Controller must have appropriate line and control power filter to comply with EN61000-6-2.
_____________________________________________________________________________________________
Third party conformance testing conducted by TÜV America.
TÜV SÜD America Inc.
Suite 104
1774 Old Highway 8 NW
New Brighton, MN 55112-1891
_________________________________________________________________________________________________
Name of Authorized Representative: Cory Watkins
Title of Authorized Representative: President
Place of Issue: Chanhassen, Minnesota, USA
Date of Issue: December 2010
_____________________________________ _______________
Signature of Authorized Representative Date
DECLARATION OF CONFORMITYDECLARATION OF CONFORMITY
iii © Control Concepts Inc., 2013
www.ccipower.com 1-800-765-2799
Compact FUSION Manual Certications
External EMI filters must be used in conjunction with the FUSION series power controllers to maintain CE
immunity* approval. The following filters were used during the immunity testing.
Universal input power: Line input power:
Schaffner filter Schaffner filter
P/N: FN 2030-3-06 P/N: FN 3270H-35-33
The Schaffner filter for universal input power, or it’s equivalent, may be used as listed above. The line input
power filter however, will need to be sized accordingly for your load. Please contact Schaffner EMC Inc. for
help finding the appropriate filter. Schaffner EMC Inc.
52 Mayfield Avenue | Edison, New Jersey 08837 / USA
T 1-800-367-5566 | T 732-225-9533 | F 732-225-4789
usasales@schaffner.com | http://www.schaffner.com/us
*No filtering is required for emissions.
Wire filters as shown below:
1 Phase Controller 3 Phase Controller
Other wire diagrams are available, for models not listed here, by contacting Control Concepts, Inc.
ATTENTION
This product has been designed for class A equipment. Use of this product in domestic environments may cause
radio interference, in which case the user may be required to employ additional mitigation methods.
NOTICE
This product has been designed for environment A. Use of this product in environment B may cause unwanted
electromagnetic disturbances, in which case the user may be required to take adequate mitigation measures.
100-240
Vac
Line A Line B Line C
LineI nput
Filter
AC/LAC/N
FN2030
-3-06
PEG ND PEG ND
PEG ND
100-240Re f A
Vac
L
O
A
D
Load A
PEG ND
Line A Line BAC/LAC/N PEG ND
FN2030
-3-06
LineI nput
Filter
PEG ND
1 1
2
111
iv
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© Control Concepts Inc., 2013 Compact FUSION Manual Certications
This document certifies that Control Concepts, Inc’s products listed in the table are fully RoHS complient as
of Nov 13, 2009 in accordance with EU RoHS Directive 2002/95/EC. The products listed in the table have
been identified as RoHS compliant do not exceed the maximum limit for the six substances: Lead, Mercury,
Cadmium, Hexavalent chromium, Polybrominated biphenyls and Polybrominated diphenyl ether.
FUSION FUSION- - - - - - 11/13/2009
FUSION CF CF- - - - - - 12/20/2010
Authorized Signature Date Last Updated
Cory Watkins, President
CONTROL CONCEPTS, INC.
18760 LAKE DRIVE EAST
CHANHASSEN, MN 55317
(952) 474-6200
1-800-765-2799
FAX (952) 474-6070
www.ccipower.com
CERTIFICATE OF COMPLIANCECERTIFICATE OF COMPLIANCE
PB-FREE/REDUCTION OF HAZARDOUS SUBSTANCE (RoHS)
1
© Control Concepts Inc., 2013
www.ccipower.com 1-800-765-2799
Compact FUSION Installation Manual Revision 3.50.2
1. RECOMMENDED FUSING1. RECOMMENDED FUSING
Controllers are equipped with fast acting, branch-rated Class T fuse(s). To keep certifications (UL,
CE, etc) it is important that blown fuses are replaced with fuses of the same size and type as those
originally provided with the controller. The table below shows controller sizes with their installed fuse
size. It is also important to use this chart when external fuses are required.
Frame Size Fuse Size (Amps)
600 V Rated CCI P/N for Class T
10A 15 Fast Acting T 0042110-0460-315
25A 30 Fast Acting T 0042110-0460-325
50A 60 Fast Acting T 0042110-0460-350
80A 100 Fast Acting T 0042110-0460-410
100A 125 Fast Acting T 0042110-0460-412
125A 150 Fast Acting T 0042110-0460-415
160A 200 Fast Acting T 0042110-0460-420
Control Concepts carries an inventory of fuses and fuse blocks for purchase.
2© Control Concepts Inc., 2013
www.ccipower.com 1-800-765-2799
Compact FUSION Installation Manual Revision 3.50.2
Keep out area for top and bottom:
Mount 10 and 25 Amp controllers and a 1 zone 50 Amp single phase controller vertically for
convection cooling. All other controllers have forced air cooling and may be mounted horizontally or
vertically.
The keep out area on the top and bottom must be maintained for air circulation. The top and bottom
of the controller must have a minimum of 3.00 [76.2] free from obstructions as measured from fan
guards. Dimensions above are measured from the edge of the base plate.
Mounting hardware: 1/4-20 or M6 bolts with flat and lock washers (not provided)
P1, P2 and P3 protrude approximately 0.50 [12.7] from the left side of this figure. When using the
remote display, this distance is approximately 2.25 [57.2]. They are required for operation but
may be removed for wiring. It is important to leave enough room for the removal of the connectors
(approximately 1.00 [25.4] - More if using Remote Display) and wiring considerations.
CAD Blocks are available for download at www.ccipower.com.
Keep Out Area
Air Flow
2. INSTALLATION2. INSTALLATION
2.1 Mounting Considerations
*Depth with DeviceNet adaptor is 9.82 [249.4]
A1.82 [46.2]
B 2.31 [58.7]
Depth* 9.57 [243.0]
B
A
P1
P2
P3
Remote
Display
Dimensions:
Inches [mm]
3
© Control Concepts Inc., 2013
www.ccipower.com 1-800-765-2799
Compact FUSION Installation Manual Revision 3.50.2
This model includes controllers:
• Single Phase
• Single Phase with Pass Through
• (2x) Single Phase
• Three Phase Two Leg
2.2 Mounting Dimensions for Single Module Controllers
Height
14.03 [356.5]
Width
5.96 [151.4]
Depth
9.57 [243.0] *
*Depth with DeviceNet adaptor is 9.82 [249.4]
Amp Weight (lbs[kg])**
10-50 14.0 - 15.5 [6.4-7.0]
80-125 14.0 - 15.5 [6.4-7.0]
160 15.5 - 17.5 [7.0-7.9]
** Weights are for controller only - Shipping
weight will vary
Dimensions:
Inches [mm]
PE GROUND M6 STU D
13.44
[341.4]
14.03
[356.5]
0.487 [12.4]
0.345 [8.8]
0.98 [24.8]
4.09 [103.9]
5.96 [151.4]
Ø0.281 [7.1]
R0.141 [3.6]
R0.313 [8]
0.50 [12.7]
Tabla de contenidos
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