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A C /N
A C /L
P E G N D
A C /N
A C /L
P E G N D
FUSION
1 00 -2 40
V ac
1 00 -2 40
V ac
SCR POWER CONTROLLERS
INSTALLATION &
MAINTENANCE MANUAL
FUSION Installation Manual Revision 350.3
Load A2
Loa d B2
L
Load A2
Loa d B2
O
A
D
L
O
A
D
L O A D
www.ccipower.com
www.ccipower.com
Load C2
Load C2
1-800-765-2799
1-800-765-2799
© Control Concepts Inc., 2014
© Control Concepts Inc., 2014
Line A1
Line B1
Line A1
Line C1
F u ses
Line B1
Line C1
F u ses
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Table of Contents
Related Manuals for Control Concepts Fusion
Summary of Contents for Control Concepts Fusion
- Page 1 INSTALLATION & MAINTENANCE MANUAL Load A2 Loa d B2 Load C2 Load A2 Loa d B2 Load C2 L O A D www.ccipower.com www.ccipower.com 1-800-765-2799 1-800-765-2799 © Control Concepts Inc., 2014 © Control Concepts Inc., 2014 FUSION Installation Manual Revision 350.3...
- Page 2 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS DECLARATION OF CONFORMITY .....................ii CERTIFICATE OF COMPLIANCE ....................iv 1. RECOMMENDED FUSING ..................... 1 2. INSTALLATION ........................2 2.1 Mounting Considerations for All AC Controllers ............2 2.1.1 Single Phase One Zone (50-400 Amps) ............3 2.1.2 Single Phase, Two Zone (50-400 Amps) ............4 Three Phase - Two Leg (50-400 Amps) .............. - Page 4 100kA Short Circuit Current Rating* File Number E136219 *On select models with appropriate fusing. EN60947-4-3 IP 20 See CE Declaration of Conformity Part 15 Subpart B Class A Device See RoHS Certificate of Compliance FUSION Manual Certifications © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799...
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Page 5: Declaration Of Conformity
Model Numbers: Model Fusion followed by ZC, PA or DC, followed by 1, 2 or 3, followed by 1 through 9 or A through E, followed by O, S or E, may be followed by numbers and/or letters, may be followed by numbers and/or letters, may be followed by NS, may be followed by numbers and/or letters. - Page 6 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.
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Page 7: Certificate Of Compliance
CERTIFICATE OF COMPLIANCE CERTIFICATE OF COMPLIANCE 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. -
Page 8: Recommended Fusing
1500 Fast Acting L 0042270-0460-515 (Fast Acting L) * UL listed but not CSA approved. Contact Control Concepts for information on CSA approved fusing. Control Concepts carries an inventory of branch-rated fuses and fuse blocks for customers to purchase. © Control Concepts Inc., 2014 www.ccipower.com... -
Page 9: Installation
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. FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799... -
Page 10: Single Phase One Zone (50-400 Amps)
17 [7.7] PE GROUND M6 STU D R0.141 [3.6] 0.50 [12.7] R0.313 [8] 13.44 [341.4] 14.03 [356.5] 0.345 [8.8] Ø0.281 [7.1] 0.487 [12.4] 0.98 [24.8] 4.09 [103.9] 5.96 [151.4] © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 11: Single Phase, Two Zone (50-400 Amps)
28.5 [13.0] PE GROUND M6 STU D R0.141 [3.6] 0.50 [12.7] R0.313 [8] 13.44 [341.4] 14.03 [356.5] 0.345 [8.8] Ø0.281 [7.1] 0.487 [12.4] 4.08 [103.6] 7.73 [196.3] 9.61 [244.1] FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014... -
Page 12: Single Phase, Three Zone (50-400 Amps)
PE GROUND M6 STU D R0.141 [3.6] 0.50 [12.7] R0.313 [8] 13.44 [341.4] 14.03 [356.5] 0.345 [8.8] Ø0.281 [7.1] 0.487 [12.4] 4.08 [103.6] 7.73 [196.3] 11.38 [289.1] 13.27 [337.1] © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 13: Single Phase, Four Zone (50-400 Amps)
PE GROUND M6 STU D R0.141 [3.6] 0.50 [12.7] R0.313 [8] 13.44 [341.4] 14.03 [356.5] 0.345 [8.8] Ø0.281 [7.1] 0.487 [12.4] 4.08 [103.6] 7.73 [196.3] 11.38 [289.1] 15.03 [381.8] 16.94 [430.3] FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014... -
Page 14: Single Phase, One Zone (500-1200 Amps)
50 [22.7] PE GROUND M8 STU D R0.172 [4.4] 0.55 [14.0] R0.4 [10.2] 19.80 [502.9] 20.49 [520.3] Ø0.344 [8.7] 0.387 [9.8] 0.472 [12.0] 0.98 [24.8] 7.89 [200.4] 9.22 [234.1] © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 15: Single Phase Two Zone (500-1200 Amps)
PE GROUND M8 STU D R0.172 [4.4] 0.55 [14.0] R0.4 [10.2] 19.80 [502.9] 20.49 [520.3] 0.387 [9.8] Ø0.344 [8.7] 0.472 [12.0] 0.98 [24.8] 7.89 [200.4] 14.80 [375.9] 16.12 [409.5] FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014... -
Page 16: Single Phase Three Zone (500-1200 Amps)
PE GROUND M8 STU D R0.172 [4.4] 0.55 [14.0] R0.4 [10.2] 19.80 [502.9] 20.49 [520.3] 0.387 [9.8] Ø0.344 [8.7] 0.472 [12.0] 0.98 [24.8] 7.89 [200.4] 14.80 [375.9] 21.71 [551.4] 23.03 [585.0] © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 17: Single Phase, Four Zone (500-1200 Amps)
R0.172 [4.4] 0.55 [14.0] R0.4 [10.2] 19.80 [502.9] 20.49 [520.3] Ø0.344 [8.7] 0.387 [9.8] 0.472 [12.0] 0.98 [24.8] 7.89 [200.4] 14.80 [375.9] 21.71 [551.4] 28.62 [727.0] 29.93 [760.2] FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014... -
Page 18: Mounting Considerations For All Dc Controllers
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. © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 19: Single Phase (45 - 360 Amps) Dc
9.57 [243.0] PE GROUND M6 STU D R0.141 [3.6] 0.50 [12.7] R0.313 [8] 13.44 [341.4] 14.03 [356.5] 0.345 [8.8] Ø0.281 [7.1] 0.487 [12.4] 4.08 [103.6] 7.73 [196.3] 12.87 [326.9] FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014... -
Page 20: Single Phase (720 - 1080 Amps) Dc
PE GROUND M8 STU D R0.172 [4.4 0.55 [14.0] R0.4 [10.2] 19.80 [502.9] 20.49 [520.3] 0.387 [9.8] Ø0.344 [8.7] 0.472 [12.0] 0.98 [24.8] 7.89 [200.4] 14.80 [375.9] 20.02 [508.5] © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 21: Three Phase (60 - 490 Amps) Dc
PE GROUND M6 STU D R0.141 [3.6] 0.50 [12.7] R0.313 [8] 13.44 [341.4] 14.03 [356.5] 0.345 [8.8] Ø0.281 [7.1] 0.487 [12.4] 4.08 [103.6] 7.73 [196.3] 11.38 [289.1] 15.03 [381.8] 20.18 [512.6] FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014... -
Page 22: Three Phase (975-1400 Amps) Dc
R0.172 [4.4] 0.55 [14.0] R0.4 [10.2] 19.80 [502.9] 20.49 [520.3] 0.387 [9.8] Ø0.344 [8.7] 0.472 [12.0] 0.98 [24.8] 7.89 [200.4] 14.80 [375.9] 21.71 [551.4] 28.62 [727.0] 33.83 [859.3] © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 23: Remote Display Kit
3.627 [92.1] 3.627 [92.1] Must be mounted on enclosure with smooth surface. Follow the mounting instructions on the following pages for proper installation. Maximum panel thickness: 0.25 [6.4]. FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014... -
Page 24: Mounting Instructions
(See Number 2, bottom left) STEP Remove the display from the lid. The four tabs holding the display into the lid are marked. (See Number 3 bottom right) © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... - Page 25 Concepts for a replacement. When the controller is supplied with the Universal input power [100-240 Vac] the display shall now operate the same as when mounted on the controller FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014...
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Page 26: Wiring
3. WIRING Control Concepts configures and tests each controller before shipping. Once received, the controller is ready to install. The following sections will describe how to properly wire the unit with the recommended fusing. For line and load connections use copper conductors rated 75°C minimum. In the wiring drawings the wire acceptance is listed with the entry heights. -
Page 27: Universal Input Power
3Ø - 2 Leg 35.3 46.9 68.5 89.4 3Ø - 3 Leg 29.3 61.7 94.1 125.4 45-60A 90-290A 360-490A 720-1400A 1Ø DC 25.3 46.9 68.5 89.4 3Ø DC 29.3 72.5 104.9 FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014... -
Page 28: Ac Cable Entry Heights / Wire Acceptance
(2) 1/0 - 250 MCM or Drive [10] (1) 350 - 750 MCM 320-400 3/8” Hex (2) 1/0 - 250 MCM or Drive [10] (1) 350 - 750 MCM © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 29: Dc Cable Entry Heights / Wire Acceptance
1Ø 360 6.342 [161.1] 3/8” Hex (2) 1/0 - 250 MCM or 3/8” Hex 1/0 - 500 MCM 3Ø 490 Drive [10] (1) 350 - 750 MCM Drive [9] FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014... -
Page 30: Single Phase (720 - 1080 Amps) Dc
Drive [10] (1) 350 - 750 MCM 1Ø 1080 8.258 3/8” Hex (2) 1/0 - 250 MCM or 3Ø 1400 [209.8] Drive [10] (1) 350 - 750 MCM © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 31: Ac Line / Load Connections
This figure shows a single phase controller connected Phase A to Phase B. The controller is not phase sensitive and can be connected to any two phases. It can also be connected from Phase to Neutral. FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799... -
Page 32: Single Phase, Two Zone
The controller is not phase sensitive and any zone can be connected to any two phases. Any or all zones can be connected from Phase to Neutral. Note: During operation Zone 1 must have line power “ON” in order for other zones to operate. © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 33: Single Phase, Three Zone
The controller is not phase sensitive and any zone can be connected to any two phases. Any or all zones can be connected from Phase to Neutral. Note: During operation Zone 1 must have line power “ON” in order for other zones to operate. FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799... -
Page 34: Single Phase, Four Zone
The controller is not phase sensitive and any zone can be connected to any two phases. Any or all zones can be connected from Phase to Neutral. Note: During operation Zone 1 must have line power “ON” in order for other zones to operate. © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 35: Three Phase - Two Leg
This figure shows a three phase two leg controller connected to either a Delta or 3 Wire Wye load. Note: An optional current transducer may be ordered for monitoring the current on the third leg that does not run through the controller. Contact Control Concepts for more details. FUSION Installation Manual Revision 3.50.3 www.ccipower.com... -
Page 36: Three Phase - Three Leg - Delta Or Three Wire Wye
Load B2 Load C2 Delta or Wye Load LO AD This figure shows a three phase three leg controller connected to either a Delta or 3 Wire Wye load. © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 37: Three Phase - Three Leg - Inside Delta
(Delta or 3 Wire Wye). Both wire harnesses are necessary to perform this task. For ordering details see Appendix B in the Operator Manual. The model number configuration data is 0001. FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014... -
Page 38: Three Phase - Three Leg - Four Wire Wye
Wire Wye operation. The Fusion controllers normally display line and load voltages from Line to Line. When the controller is in 4 Wire Wye operation the line voltages read Line to Line while the load voltages read Line to Neutral. -
Page 39: Dc Line / Load Connections
PE GND Phase B Line A1 Line B1 Fu se s 10 0- 24 0 Va c This shows a single phase DC controller connected to a DC load. FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 © Control Concepts Inc., 2014... -
Page 40: Three Phase - Dc
Line C1 10 0- 24 0 Va c Fr ee Wh ee ling Di od e This shows a three phase DC controller connected to a DC load. © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 41: Connectors
POT 1 POT 2 Note: The FUSION power controller has two analog setpoints: SP1 and SP2. On a single zone controller, either can be selected to control this zone. On a 2 zone controller, SP1 is used to control zone 1 and SP2 is used to control zone 2. On controllers with more than 2 zones, a digital interface must be ordered for communication with all zones. -
Page 42: Sync-Guard
When using this feature, one and only one controller should have the SYNC-GUARD™ resistor enabled via the Fusion Control Panel. See Fusion Control Panel software manual for more details. The figures below show the total current as a... -
Page 43: Aux I/O Card (Optional)
Voltage output: 0-10 Vdc, 20 mA max Current output: 0-20 mA, 15 Vdc compliance For selecting voltage or current mode for the retransmits, connecting to the Fusion Control Panel Software is required. See the Fusion Control Panel Software manual for details. -
Page 44: Appendix A: Changing From Inside Delta To Delta Or 3-Wire Wye Load
NOTE: Delta loads and 3 Wire Wye loads use the same wire harness. After changing wire harness, change the Three Phase Load Config (SP 80) in the FUSION control panel software. © Control Concepts Inc., 2014 www.ccipower.com 1-800-765-2799 FUSION Installation Manual Revision 3.50.3... -
Page 45: Appendix B: Changing From 4 Wire Wye To Delta Or 3-Wire Wye Load
Phase - Three Leg section of the manual. NOTE: Delta loads and 3 Wire Wye loads use the same wire harness. After changing wire harness, change the Three Phase Load Config (SP 80) in the FUSION control panel software. FUSION Installation Manual Revision 3.50.3 www.ccipower.com 1-800-765-2799 ©...
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